|
| |
Aluminum |
Magnesium |
Zinc |
Zinc-Aluminum |
| Cost |
Lowest Cost per unit volume |
Can compete with aluminum if thinner wall sections are used. Faster hot-chamber process possible on smaller parts. |
Effective production of miniature parts. Significant long-term tooling cost savings (tooling lasts 3-5 times longer than aluminum).
|
|
| Weight |
Second lowest in density next to magnesium.
|
Lowest density.
|
Heaviest of die cast alloys, but castable with thinner walls than aluminum, which can offset the weight disadvantage.
|
Weight reduction as coMPared with the Zinc family of alloys.
|
| Structural Properties |
Highest Modulus of Elasticity
|
Highest strength-to-weight ration, best vibration dampening characteristics.
|
Highest ductility and iMPact strength
|
Highest tensile and yield strength.
|
| Surface Finish & Coatings |
Good choice for Coating processes that require high temperatures
|
Good as-cast surface finishes can be achieved
|
Best as-cast surface finish readily accepts electro-coatings and decorative finishes
|
|
| Wear Resistance |
* |
* |
* |
Best as-cast wear resistance |
| Corrosion Resistance |
* |
* |
* |
* |
| Machinability |
Good |
Best machinability in terms of tool-life, achievable finish, low cutting forces and energy consumption
|
Good |
Good |
| Thermal Properties, Conductive, & Electromagnetic Shielding
|
Best choice for heat transfer. Good electrical conductivity
|
Electro-magnetic shielding
|
Best electrical conductor. Good heat transfer
|
|
* Wear and corrosion resistance can be improved in all alloys through surface treatments and coatings.
Die Casting Alloys: Composition, Mechanical Properties, Physical Properties and Characteristics
The following information is for reference only
| Detailed Composition |
|
Commercial |
A360 |
A380 |
A384 |
218 |
|
ANSI/AA |
A360.0 |
A380.0 |
A384.0 |
518.0 |
| Silicon Si |
9.0-10.0 |
7.5-9.5 |
10.5-12.0 |
.35 |
| Iron Fe |
1.30 |
1.30 |
1.30 |
1.80 |
| Copper Cu |
0.60 |
3.0-4.0 |
3.0-4.5 |
0.25 |
| Magnesium Mg |
0.4-0.6 |
0.10 |
0.10 |
7.5-8.5 |
| Manganese Mn |
0.35 |
0.50 |
0.50 |
0.35 |
| Nickel Ni |
0.50 |
0.50 |
0.50 |
0.15 |
| Zinc Zn |
0.50 |
3.00 |
3.00 |
0.15 |
| Tin Sm |
0.15 |
0.35 |
0.35 |
0.15 |
| Titanium Ti |
- |
- |
- |
- |
| Others Each |
- |
- |
- |
- |
| Total Others |
0.25 |
0.50 |
0.50 |
0.25 |
| Aluminum AL |
Balance |
Balance |
Balance |
Balance |
| Mechanical Properties |
|
Commercial |
A360 |
A380 |
A384 |
218 |
|
ANSI/AA |
A360.0 |
A380.0 |
A384.0 |
518.0 |
Ultimate Tensile Strength
ksi (MPa) |
46 (317) |
47 (324) |
48 (330) |
45 (310) |
Yield Strength
ksi (MPa) |
24 (170) |
23 (160) |
24 (165) |
28 (193) |
Elongation
% in 2" (51mm) |
3.5 |
3.5 |
2.5 |
5.0 |
Hardness
BHN |
75 |
80 |
85 |
80 |
Shear Strength
ksi (MPa) |
26 (180) |
27 (190) |
29 (200) |
29 (200) |
Impact Strength
ft-lb(J) |
- |
- |
- |
7 (9) |
Fatigue Strength
ksi (MPa) |
18 (120) |
20 (140) |
20 (140) |
20 (140) |
Young's Modulus
Psi x 106 (GPa) |
10.3 (71) |
10.3 (71) |
- |
- |
| Physical Properties |
Density
lb/in3 (g/cm3) |
0.095 (2.63) |
0.098 (2.71) |
0.102 (2.82) |
0.093 (2.57) |
Melting Range
°F(⁰C) |
1035-1105 (557-596) |
1000-1100 (540-595) |
960-1080 (516-582) |
995-1150 (535-621) |
Specific heat
BTU/lb°F (J/kg⁰C) |
0.230 (963) |
0.230 (963) |
|
|
Coefficient of Thermal Expansion
μ in/in°F (μ m/m°K) |
11.6 (21.0) |
12.1 (21.8) |
11.6 (21.0) |
13.4 (24.1) |
Thermal Conductivity
BTU/ft hr°F (W/m°K) |
65.3 (113) |
55.6 (96.2) |
55.6 (96.2) |
55.6 (96.2) |
Electrical Conductivity
% IACS |
29 |
23 |
22 |
24 |
| Poisson's Ratio |
0.33 |
0.33 |
- |
- |
Characteristics
1 = most desirable, 5 = least desirable |
|
Commercial |
A360 |
A380 |
A384 |
218 |
|
ANSI/AA |
A360.0 |
A380.0 |
A384.0 |
518.0 |
| Anodizing appearance ① |
3 |
3 |
4 |
1 |
| Chemical Oxide Protective Coating ② |
3 |
4 |
5 |
1 |
| Corrosion Resistance ③ |
2 |
4 |
5 |
1 |
| Electroplating Ease & Quality ④ |
2 |
1 |
2 |
5 |
| Machining Ease & Quality ⑤ |
3 |
3 |
3 |
0.15 |
| Polishing Ease & Quality ⑥ |
3 |
3 |
3 |
1 |
| Pressure Tightness |
2 |
2 |
2 |
5 |
| Resistance to Hot Cracking ⑦ |
1 |
2 |
2 |
5 |
| Strength at Elevated Temp. |
1 |
3 |
2 |
4 |
① Rated on lightness of color, brightness, and uniformity of clear anodized coating applied in sulphuric acid electrolyte
② Rated on combined resistance of coating and prolonged heating at testing temperature
③ Based on resistance of alloy in standard type salt spray test
④ Ability of the die casting to take and hold an electroplate applied by present standard methods
⑤ Composite rating based on ease of cutting, chip characteristics, quality of finish, and tool life
⑥ Composite rating based on ease and speed of polishing and quality of finish, and tool life
⑦ Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature ranges
Sources: ASTM B85-92a; ASM; SAE
Die Casting Alloys: Composition, Mechanical Properties, Physical Properties and Characteristics
The following information is for reference only
| Detailed Composition |
|
Commercial |
#3 Zinc |
ZA-8 |
ZA-12 |
ZA-27 |
|
ANSI/AA |
AG-40A |
|
|
|
| Aluminum AL |
3.5-4.3 |
8.0-8.8 |
10.5-11.5 |
25.0-28.0 |
| Magnesium Mg |
0.02-0.05 |
0.015-0.030 |
0.015-0.030 |
0.010-0.020 |
| Copper Cu |
0.25 Max |
0.8-1.3 |
0.5-1.2 |
2.0-2.5 |
| Iron Fe(max) |
0.10 |
0.075 |
0.075 |
0.075 |
| Lead Pb (max) |
0.005 |
0.006 |
0.006 |
0.006 |
| Cadmium CD (max) |
0.004 |
0.006 |
0.006 |
0.006 |
| Tin Sm(max) |
0.003 |
0.003 |
0.003 |
0.003 |
| Nickel Ni |
- |
- |
- |
- |
| Zinc Zn |
Balance |
Balance |
Balance |
Balance |
| Mechanical Properties |
|
Commercial |
#3 Zinc |
ZA-8 |
ZA-12 |
ZA-27 |
|
ANSI/AA |
AG-40A |
|
|
|
Ultimate Tensile Strength
Cast ksi (MPa)
Aged ksi (MPa) |
41 (283)
35 (241) |
54 (372)
43 (297) |
59 (400)
45 (310) |
462 (426)
52 (359) |
Yield Strength
Cast ksi (MPa)
Aged ksi (MPa) |
32 (221) |
41-43 (283-296)
32 (224) |
45-48 (310-331)
35 (245) |
52-55 (359-379)
46 (322) |
Compressive Yield Strength
Cast ksi (MPa)
Aged ksi (MPa) |
60 (414)
60 (414) |
37 (252)
25 (172) |
39 (269)
27 (186) |
52 (358)
37 (255) |
Elongation
As Cast % in 2" (51mm)
Aged % in 2" (51mm) |
10
16 |
6-10
20 |
4-7
10 |
2.0-3.5
3 |
Hardness
As Cast BHN
Aged BHN |
82
72 |
100-106
91 |
95-105
91 |
116-122
100 |
Shear Strength
As Cast Ksi (MPa)
Aged Ksi (MPa) |
31 (214)
31 (214) |
40 (275)
33 (228) |
43 (296)
33 (228) |
47 (325)
37 (255) |
Impact Strength
As Cast Ft-Lb
Aged Ft-Lb (J) |
43
41 (58) |
24-35
13 (32-48) |
15-27
14 (20-37) |
7-12
3.5 (9-16) |
Fatigue Strength
As Cast Ksi (MPa)
Aged Ksi (MPa) |
6.9 (47.6)
6.9 (47.6) |
15 (103)
15 (103) |
- |
21 (145)
21 (145) |
Young's Modulus
Psi x 106 (GPa) |
- |
12.4 (85.5) |
12 (83) |
11.3 (77.9) |
| Physical Properties |
Density
lb/in3 (g/cm3) |
0.24 (6.6) |
0.227 (6.3) |
0.218 (6.03) |
0.181 (5.000) |
Melting Range
°F(⁰C) |
718-728 (381-387) |
707-759 (375-404) |
710-810 (377-432) |
708-903 (372-484) |
Specific heat
Btu/lb.°F (J/kg⁰C) |
0.10 (419) |
0.104 (435) |
0.107 (450) |
0.125 (525) |
Coefficient of Thermal Expansion
μ in./in. x10-6 (μ m/m°k) |
15.2 (27.4) |
12.9 (23.2) |
13.2 (24.1) |
14.4 (26.1) |
Thermal Conductivity
Btu/ft hr.°F (W/m °k) |
65.3 (113) |
66.3 (115) |
67.1 (116) |
72.5 (122.5) |
Electrical Conductivity
μ Ω in. |
27 |
27.7 |
28.3 |
29.7 |
| Poisson's Ratio |
0.30 |
0.30 |
0.30 |
0.30 |
Characteristics
1 = most desirable, 5 = least desirable |
|
Commercial |
#3 Zinc |
ZA-8 |
ZA-12 |
ZA-27 |
|
ANSI/AA |
AG-40A |
|
|
|
| Anodizing Protection |
1 |
1 |
2 |
2 |
| Chemical Coating Protection |
1 |
2 |
3 |
3 |
| Corrosion Resistance |
3 |
2 |
2 |
1 |
| Electroplating Ease & Quality ① |
1 |
1 |
2 |
3 |
| Machining Ease & Quality ② |
1 |
2 |
3 |
4 |
| Polishing Ease & Quality |
1 |
2 |
3 |
4 |
| Pressure Tightness |
1 |
3 |
3 |
4 |
| Resistance to Hot Cracking ③ |
1 |
2 |
3 |
4 |
① Ability of the die casting to take and hold an electroplate applied by present standard methods
② Composite rating based on ease of cutting. Chip characteristics, quality of finish and tool life
③ The ability of alloy to resist formation of cold defects: for example, cold shuts , cold cracks, non-fill "woody" areas, swirls, etc.
Sources: ASTM B85-92a; ASM; SAE
For more specific information, refer to NADCA Product
Specification Standards for Die Castings.
|
