HYDieCasting
Die casting, a precise and efficient metal manufacturing process, is highly favored across industries for producing complex, high-volume metal parts with superior surface finishes. This method's success hinges on selecting suitable die casting materials, which impacts factors like production efficiency, cost, strength, and longevity of the final product. Generally, die casting materials are non-ferrous metals such as aluminum, zinc, and magnesium alloys. While ferrous metals are occasionally used, non-ferrous metals dominate due to their favorable casting properties, corrosion resistance, and lightweight characteristics.
This guide covers core materials—primarily non-ferrous metals like aluminum, zinc, and magnesium—highlighting each one's suitability for high-volume production and compatibility with metal casting processes, such as hot and cold-chamber die casting.
Aluminum is a popular die casting material thanks to its lightweight and excellent mechanical properties. Known for its high corrosion resistance, thermal stability, and electrical conductivity, aluminum alloys are especially valued in industries requiring both durability and weight reduction, such as automotive and aerospace. Common aluminum die casting alloys include:
Aluminum alloys are primarily used in cold-chamber die casting due to their high melting points, which can cause contamination if processed in hot-chamber systems.
Zinc alloys are easy to cast, offering excellent impact strength and dimensional stability. They are ideal for producing complex, small parts in high volumes, commonly used in consumer electronics, automotive, and household fixtures. Zinc is particularly well-suited for hot-chamber die casting, thanks to its low melting point and durability. Key zinc alloys include:
Zinc alloys are cost-effective, provide excellent surface finish, and are ideal for parts requiring plating or surface treatments.
Magnesium alloys are valued for their exceptional machinability and lightweight properties, with a weight approximately 33% lighter than aluminum. Magnesium is preferred for applications needing lightweight, durable materials, such as consumer electronics and high-performance vehicles. Typical magnesium alloys include:
Magnesium alloys are often compatible with hot-chamber die casting, enhancing casting speed and production efficiency.
With advancements in material technology, hybrid and composite die casting alloys are increasingly used. These materials combine the strengths of different metals, yielding innovative alloys for specialized needs in sectors like renewable energy and medical devices. These emerging materials, including zinc-aluminum composites and sustainable alloys, support unique design specifications and regulatory compliance.
Die casting materials vary in compatibility with hot and cold-chamber processes, primarily due to their melting points and reaction to the casting environment.
| Material | Hot-Chamber Compatibility | Cold-Chamber Compatibility | Key Applications |
|---|---|---|---|
| Aluminum | No | Yes | Automotive, aerospace, electronic housings |
| Zinc | Yes | Yes | Consumer goods, electronics, automotive |
| Magnesium | Yes | Yes | Automotive, electronics, medical devices |
| Copper | No | Yes | Electrical components, plumbing fixtures |
| Lead/Tin | Yes | Limited | Radiation shielding, bearings, soldering |
Hot-Chamber Die Casting is faster and best suited for metals with low melting points, such as zinc and magnesium, while Cold-Chamber Die Casting is more appropriate for materials with higher melting points like aluminum and copper. This compatibility table helps guide the selection of die casting processes based on material properties.
Each die casting material offers unique mechanical and physical properties that influence performance across applications. Here, we compare essential factors:
| Alloy | Elongation (% in 50mm) | Tensile Strength (PSI x 10³) | Yield Strength (0.2%) (PSI x 10³) | Impact Strength (ft lb) | Shear Strength (PSI x 10³) | Hardness (Brinell HB) | Process |
|---|---|---|---|---|---|---|---|
| Aluminum Alloy A380 | 3.5 | 47 | 23 | 3 | 27 | 80 | Cold Chamber Die Casting |
| AZ91D | 3 | 34 | 23 | 2 | 20 | 63 | Hot Chamber Die Casting |
| Aluminum Alloy 383 | 3.5 | 45 | 22 | 3 | - | 75 | Cold Chamber Die Casting |
| B390 | 1 | 46 | 36 | - | - | 120 | Cold Chamber Die Casting |
| A413 | 3.5 | 42 | 19 | - | 25 | 80 | Cold Chamber Die Casting |
| Zamak 2 | 7 | 52 | 41 | 35 | 46 | 100 | Hot Chamber Die Casting |
| 413 | 2.5 | 43 | 21 | - | 25 | 80 | Cold Chamber Die Casting |
| K-Alloy | 5 | 43 | 25 | - | - | 80 | Cold Chamber Die Casting |
| Zamak 3 | 10 | 41 | 32 | 43 | 31 | 82 | Hot Chamber Die Casting |
| A360 | 3.5 | 46 | 24 | - | 26 | 75 | Cold Chamber Die Casting |
| Zamak 5 | 7 | 48 | 33 | 48 | 38 | 91 | Hot Chamber Die Casting |
| Zamak 7 | 13 | 41 | 32 | 43 | 31 | 80 | Hot Chamber Die Casting |
| ZA 8 | 10 | 54 | 42 | 31 | 40 | 103 | Hot Chamber Die Casting |
| ACuZinc5 | 5 | 59 | 49 | - | - | 115 | Hot Chamber Die Casting |
| EZAC | 6.7 | 60 | 57 | - | - | - | - |
Understanding these differences helps manufacturers align material choice with performance needs, optimizing cost-efficiency and product functionality.
For manufacturers, choosing the right die casting material is a complex decision influenced by various factors. This selection guide simplifies the process:
Key Factors in Material Selection:
These considerations help ensure optimal material selection for parts or prototypes, balancing performance and production efficiency.
Choosing the right die casting material is key to achieving a balance of cost, efficiency, and product quality. This guide equips manufacturers with insights into core materials—aluminum, zinc, and magnesium—and new alloys to meet industry demands across automotive, electronics, and medical fields. For tailored recommendations, consulting a die casting expert can further ensure the best material choice for high-performance results.
At HYDieCasting, we specialize in producing high-quality die-cast parts tailored to your specific needs, using materials and processes that align with industry standards. Whether you're looking for prototypes or large-scale production, our expert team is here to guide you through material selection and process compatibility.
Contact HYDieCasting today by lily@huayin99.com to discuss how we can support your project with precision, efficiency, and exceptional results.