Die Casting Description: Molten Metal is injected, under pressure, into hardened steel die casting dies, often water-cooled. The die casting dies are opened, and die castings are ejected. Many times thousands of die casting parts each day are produces.

Metal:

• Aluminum 360, aluminum die casting alloy
• Aluminum 380, aluminum die casting alloy
• Aluminum 383, aluminum die casting alloy
• Aluminum 413, aluminum die casting alloy
• Zinc die casting alloys
• ZA die casting alloys

Size Range: Not normally over 2 feet square.

Tolerances:

• Aluminum ± .002"/in
• Zinc ± .0015"/in
• Add ± .001" to ±.015" across parting line depending on size

Surface Finish: 32-63RMS

Minimum Draft Requirements:

• Aluminum & Mag 1° to 3°
• Zinc 1/2° to 2°

Normal 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 differences of Aluminum, ZA & Zinc #3 die casting alloys.
(1= most desirable, 5= least desirable):

 

ALLOY
	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 weighs 2.44 times more than aluminum, the ZA-8 weighs 2.3 times more than aluminum, and the ZA-27 weighs 1.84 times more than aluminum and the greater weight will effect the overall part cost.