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Aluminum Die Casting Description: Molten Aluminum Metals (aluminum die casting alloys) are injected, under pressure,
into hardened steel die casting dies, often water-cooled. The die casting dies are opened, and aluminum castings are ejected. Many times
thousands of aluminum casting parts each day are produced.
Die Casting Metals (Die Casting Alloys):
- Aluminum 360, aluminum casting alloy (A360 Die Casting Alloy)
- Aluminum 380, aluminum casting alloy (A380 Die Casting Alloy)
- Aluminum 383, aluminum casting alloy (A383 Die Casting Alloy)
- Aluminum 413, aluminum casting alloy (A413 Die Casting Alloy)
- Zinc (Zamak) die casting alloys (#3 and #5)
- ZA (Zinc-Aluminum) die casting alloys (ZA8, ZA12 and ZA27)
Size Range: Not normally over 2 feet square.
Die Casting Alloy Tolerances:
- Aluminum Alloy Die Casting Part ± .002"/in
- Zinc Alloy Die Casting Part ± .0015"/in
- Add ± .001" to ±.015" across parting line depending on size
Die Casting Part Surface Finish: 32-63RMS
Minimum Die Casting Part Draft Requirements:
- Aluminum & Mag 1° to 3°
- Zinc 1/2° to 2°
Normal Die Casting Part Minimum Section Thickness:
- Aluminum: .06" Small Parts; .09" Medium Parts
- Zinc: .03" Small Parts; .06" Medium Parts
Ordering Quantities: Usually 1,000 and up
Normal Lead Time:
- Samples: 2 to 4 weeks
- Production: Starts usually within two weeks after approval
The following table will provide a general idea of the technical differences of:
- Aluminum Die Casting Alloys (360, 380, 383 & 413),
- Zinc-Aluminum Die Casting Alloys (ZA8, ZA12 & ZA28)
- Zinc Die Casting Alloys (#3 & #5):
Aluminum Casting Alloys Technical Information
Die Casting Metals Comparison
(1= most desirable, 5= least desirable)
|
| |
360
|
380
|
383
|
413
|
ZA-8
|
ZA-12
|
ZA-27
|
#3
|
#5
|
| Hardness |
75
|
80
|
75
|
80
|
100
|
95
|
116
|
82
|
91
|
| Shear Strength (ksi) |
28
|
28
|
-
|
25
|
40
|
43
|
47
|
31
|
33
|
| Tensile Yield Strength (ksi) |
25
|
23
|
22
|
21
|
37
|
39
|
52
|
32
|
39
|
| Ultimate Tensil Strength (ksi) |
44
|
46
|
45
|
43
|
56
|
60
|
64
|
41
|
48
|
| Thermal Conductivity |
65
|
56
|
56
|
70
|
66
|
67
|
72
|
65
|
63
|
| Electrical Conductivity (% cu.) |
30
|
27
|
23
|
31
|
28
|
23
|
30
|
27
|
26
|
Density (lb./in.3)
|
.1
|
.1
|
.1
|
.1
|
.23
|
.22
|
.18
|
.24
|
.24
|
| Pressure Tightness |
2
|
2
|
2
|
1
|
3
|
3
|
4
|
1
|
2
|
| Die Filling Capacity |
3
|
2
|
1
|
1
|
2
|
3
|
3
|
1
|
1
|
| Anti-Soldering to Die |
2
|
1
|
2
|
1
|
-
|
-
|
-
|
-
|
-
|
| Corrosion Resistance |
2
|
4
|
3
|
2
|
2
|
2
|
1
|
3
|
3
|
| Machining ease & quality |
3
|
3
|
2
|
4
|
2
|
3
|
4
|
1
|
1
|
| Strength at high temps |
1
|
3
|
2
|
3
|
-
|
-
|
-
|
-
|
-
|
Zinc #3 Alloy weighs 2.44 times more than aluminum alloys, the ZA-8 alloy weighs 2.3 times more than aluminum alloys,
and the ZA-27 alloy weighs 1.84 times more than aluminum alloys and the greater weight will effect the overall die casting part cost.
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