Automotive Die Casting

Automotive Die Casting

Automotive Die Casting Manufacturer and Exporter Product Description and Process Automotive Die Casting Manufacturer and Exporter Production process: aluminum die casting process Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc. Surface treatment process:...

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Automotive Die Casting Manufacturer and Exporter

Product Description and Process

Automotive Die Casting Manufacturer and Exporter

Production process: aluminum die casting process

Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.

Surface treatment process: anodic oxidation, Dacromet coating, etc.


Product Material and Uses

Normally produce with JIS ADC1, ADC3, ADC5, ADC6, ADC10, ADC12, ASTM A413, A360, A380, A383, etc.

The aluminum casting products are widely used for electronic industry, auto-car parts, electric motor parts, aero craft parts, watercraft parts, medical treatment equipment, communication system, other machinery components, etc.


ALUMINUM  ALLOYS

Aluminum die casting alloys (Table1) are lightweight, offer good corrosion resistance, ease of casting, good mechanical properties and dimensional stability.

Although a variety of aluminum alloys made from primary or recycled metal can be die cast, most designers select standard alloys listed below:

360 — Selected for best corrosion resistance. Special alloys for special applications are available, but their use usually entails significant cost premiums.

380 — An alloy which provides the best combination of utility and cost.

383 & 384 — These alloys are a modification of 380. Both provide better die filling, but with a moderate sacrifice in mechanical properties, such as toughness.

390 — Selected for special applications where high strength, fluidity and wear-resistance/bearing properties are required.

413 (A13) — Used for maximum pressure tightness and fluidity.


COMPOSITION AND PROPERTIES OF ALUMINUM DIE CASTING ALLOYS

DESIGNATIONS
AA NUMBER

A360.0
A360.0

A380.0
A380.0

E380.0

383.0

B383.0

A413.0
A13

B390.0
390

384.0
384

FORMER NO.
COMPOSITION (in percent max. unless shown as range)

--------

Silicon

9.0-10.0

7.5-9.5

7.5-9.5

9.5-11.5

9.5-11.5

11.0-13.0

16-18

10.5-12.0

Iron

1.3

1.3

1.3

1.3

1.3

1.3

1.3

1.3

Copper

0.6

3.0-4.0

3.0-4.0

2.0-3.0

2.0-3.0

1.0

4.0-5.0

3.0-4.5

Manganese

0.35

0.50

0.50

0.50

0.50

0.35

0.50

0.50

Magnesium

0.40-0.6

0.10

0.30

0.10

0.30

0.10

0.45-0.65

0.10

Nickel

0.50

0.50

0.50

0.30

0.30

0.50

0.1

0.50

Zinc

0.50

3.0

3.0

3.0

3.0

0.50

1.5

3.0

Tin

0.15

0.35

0.35

0.15

0.15

0.15

0.2

0.35

Titanium

-

-

-

-

-

-

0.20

-

Total others

0.25

0.50

0.50

0.50

0.50

0.25

0.2

0.50

Aluminum

Bal.

Bal.

Bal.

Bal.

Bal.

Bal.

Bal.

Bal.

PROPERTIES (see notes)

--------

DESIGNATIONS
AA NUMBER

A360.0
A360.0

A380.0
A380.0

E380.0

383.0

B383.0

A413.0
A13

B390.0
390

384.0
384

Ultimate tensile strength (ksi)

46

47

47

45

45

42

40.5

48

yield strength (ksi)

24

23

23

22

22

19

35

24

Elongation    (% in 2″ G.L.)

3.5

3.5

3.5

3.5

3.5

3.5

-

1.0 -2.5

Hardness (HB)

75

80

80

80

80

120

85

-

Shear Strength (ksi)

26

27

27

25

25

29

-

-

Charpy impact strength (ft. lb.óunnotched)

4.2

3.5

3.5

-

-

2.0

-

-

Fatigue strength (ksi) (limit @ 500 million cycles)

18

20

20

19

19

20

-

20

Density (lb./in.3)

0.95

0.98

0.98

0.97

0.97

0.96

0.99

0.98

Melting range (oF) approx.

1035
-1105

1000
-1100

1000
-1100

960
-1080

960
1080

1065
-1080

945
-1200

960
-1080

Specific heat (Btu/lb.oF)

0.23

0.23

0.23

-

-

-

-

-

Coefficient of thermal expansion (in./in./oF)

11.8

11.7

11.7

11.5

11.5

10.3

11.7

11.3

Thermal conductivity (Btu/fthr.oF)

65.3

55.6

55.6

55.6

55.6

67.7

78.6

56

Electrical conductivity   (% IACS)

29

31

31

23

23

31

25

23

Modulus of elasticity (106 psi)

10.3

10.3

10.3

10.3

10.3

10.3

11.9

10.3


ZINC ALLOYS

Zinc-based alloys are the easiest for die casting. Ductility is high and impact strength is excellent, making these alloys suitable for a wide range of products.

Zinc die casting provides thin walls and excellent surface smoothness making preparation for plating and painting relatively easy.

It is essential that only high purity (99.99 + 0/0) zinc metal be used in the formulation of alloys. Low limits on lead, tin and cadmium ensure the long-term integrity of the alloy’s strength and dimensional stability.


COMPOSITION AND PROPERTIES OF ZINC DIE CASTING ALLOYS

DESIGNATIONS

ZAMAK 2

ZAMAK 3

ZAMAK 5

ZAMAK 7

ZA-8

ZA-12

ZA-27

COMPOSITION (in percent max. unless shown as range for die castings) … for ingots

-------

Aluminum

3.7-4.3

3.5-4.3

3.5-4.3

3.5-4.3

8.0-8.8

10.5-11.5

25.0-28.0

Copper

2.6-3.3

0.25

0.75-1.25

0.25

0.8-1.3

0.5-1.25

2.0-2.5

Magnesium

0.02
-0.06

0.02
-0.05

0.03
-0.08

0.005
-0.020

0.015
-0.030

0.015
-030

.010
-.020

Iron

0.05

0.1

0.1

0.075

0.1

0.075

0.1

Lead

0.005

0.005

0.005

0.003

0.004

0.004

0.004

Cadmium

0.004

0.004

0.004

0.002

0.003

0.003

0.003

Tin

0.002

0.003

0.003

0.001

0.002

0.002

0.002

Nickel

0

0

0

0.005
-0.020

0

0

0

Zinc

Bal.

Bal.

Bal.

Bal.

Bal.

Bal.

Bal.

PROPERTIES (see notes)

-------

DESIGNATIONS

ZAMAK 2

ZAMAK 3

ZAMAK 5

ZAMAK 7

ZA-8

ZA-12

ZA-27

Ultimate tensile strength (ksi)

52

40

48

41

54

58.5

61

yield strength (ksi)

41

32

39

32

42

46

53

Elongation (% in 2″ (55mm))

7

10

7

13

10

7

3

Hardness (HB)

100

82

91

80

95-110

95-115

105-125

Shear Strength (ksi)

46

31

38

0

35

37

42

Charpy impact strength (ft. lb.óunnotched)

35

43

48

43

31

21

3

Fatigue strength (ksi) (limit @ 500 million cycles)

8.5

6.9

8.2

0

7.5

15

25

Density (lb./in.3)

0.24

0.24

0.24

0.247

0.227

0.218

0.181

Melting range (oF) approx.

715-734

718-728

717-727

718-728

707-759

710-810

708-903

Specific heat (Btu/lb.oF)

0.1

0.1

0.1

0.1

0.104

0.107

0.125

Coefficient of thermal expansion (in./in./oF)

15.4

15.2

15.2

15.2

12.9

13.4

14.4

Thermal conductivity (Btu/fthr.oF)

60.5

65.3

62.9

65.3

66.3

67.1

72.5

Electrical conductivity   (% IACS)

25.0

27

26

27

27.7

28.3

29.7

Modulus of elasticity (106 psi)

0

0

0

0

10.2

10.3

10.3

Die shrinkage (in./in.)

0.007

0.007

0.007

0.007

0.007

0.0075

0.008


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