ALLOY SELECTION

Week - 2
ALLOY SELECTION

The following comparison in nine categories will assist in the selection of the optimum die casting alloy:

•Alloy cost
•Process cost
•Structural properties
•Minimum weight
•Impact strength
•Surface finish
•Corrosion resistance
•Bearing properties and wear resistance
•Machinability
 ALLOY SELECTION

Alloy Cost

Alloy cost is an important factor in overall product cost, particularly among die casting alloys. Alloy prices tend to
fluctuate with market conditions, so that any comments must be general in nature. Prices are quoted on the basis
of weight, but design is based on volume of material. The volume of metal in a die casting, whether optimized for
aluminum, magnesium, zinc or ZA, will usually be nearly constant. Therefore, cost per cubic inch is a good first
approximation of relative material cost.
Aluminum alloys usually have the lowest cost per cubic inch, which accounts for the widespread use of aluminum.
Magnesium, zinc and ZA alloys regain some of the material cost differential in applications where wall thicknesses
are controlled by casting rather than functional constraints; die casters are currently casting thinner walls in these
alloys than in aluminum.
ALLOY SELECTION

Process Cost

Process costs are another important component in overall product cost and closely related to alloy selection. Four
factors are important:

 Alloys that can be hot-chamber cast usually require smaller die casting machines that run at faster rates than
equivalent size castings that run on cold-chamber machines.
 The initial die manufacturing cost is essentially the same, regardless of the cast alloy. However, die
maintenance and replacement costs vary. They are lowest for zinc alloys because they do not attack die steels
and they are cast at relatively low temperatures. These costs increase with magnesium and ZA alloys, and
increase further with aluminum alloys.
 Magnesium, zinc and ZA alloys may reduce or eliminate finish machining operations when precision features
are required, such as zero draft and press fit tolerances, which can often be as cast in these alloys.
 Zinc alloys and ZA-8 tend to be the material of choice for very small die castings (typically less than one
ounce, or 28 gm). This advantage is attributed to die casters who have developed special purpose, highly
automated machines that produce small, “miniature” die castings at very low process costs.
ALLOY SELECTION

Structural Properties

Comparative mechanical and physical properties of die casting alloys are presented in the table “Die Casting
Alloys Material Properties Comparison.” Aluminum alloys exhibit the mid-range modulus of elasticity of the four
alloy groups. Their relatively high strength and low density make them the frequent choice for medium-to-large
die castings with structural requirements. Magnesium, with lower strength and rigidity, has been competitive with
aluminum in some applications by developing systems of thin, strategically located reinforcing ribs. In
applications where maximum strength is required within a specified space, ZA alloys, which offer the highest
ultimate and yield strengths as well as modulus of elasticity, are the best choice.
Aluminum alloys maintain their structural properties over a wider temperature range than the other alloy groups.
Their stability often makes them the material of choice at elevated temperatures, particularly where minimum or
no creep is permissible.
The creep characteristics of zinc and ZA alloys, which are similar to visco-elastic behavior of thermoplastics,
must be taken into account when long-term sustained loads induce moderate to high stress levels. Data are
available that enable the designer to predict alloy behavior and modify the design when necessary.
ALLOY SELECTION

Minimum Weight
Magnesium alloys are the dominant choice when weight must be minimized. Where weight is a major factor
and other criteria such as mechanical properties or cost are important, aluminum alloys are often competitive.
ALLOY SELECTION

Minimum Weight
Magnesium alloys are the dominant choice when weight must be minimized. Where weight is a major factor
and other criteria such as mechanical properties or cost are important, aluminum alloys are often competitive.

Impact Strength & Dent Resistance

The zinc alloys offer the highest impact strength of the four groups. However, the impact strength of the zinc
alloys begins to diminish sharply as temperature is reduced below 32°F (0°C). The impact resistance of
aluminum and magnesium alloys vary within each alloy group.
Dent resistance, as noted above, is indicated by the ratio of yield strength to modulus of elasticity. For
identical features with equal wall thicknesses, ZA-27 offers the highest dent resistance, followed by ZA-12
and ZA-8. The zinc alloys have a lower yield strength, but their nonlinear modulus of elasticity allows them to
store more elastic energy than the yield strength to modulus of elasticity ratio indicates, and increases their
dent resistance. They may be considered slightly below ZA-8, and somewhat superior to aluminum and
magnesium. The yield strength to modulus of elasticity ratios are nearly equal for aluminum and magnesium
alloys.
ALLOY SELECTION

Surface Finish
The compatibility of magnesium, zinc and ZA-8 alloys with the die steel means that a high quality finish can
be maintained over long production runs with these alloys. (Die surface quality is essential to casting surface
quality.) There are economical processes in place for depositing a bright, durable chrome finish on zinc, ZA-8
and ZA-12 die castings when this type of finish is required.
ALLOY SELECTION

Surface Finish
The compatibility of magnesium, zinc and ZA-8 alloys with the die steel means that a high quality finish can
be maintained over long production runs with these alloys. (Die surface quality is essential to casting surface
quality.) There are economical processes in place for depositing a bright, durable chrome finish on zinc, ZA-8
and ZA-12 die castings when this type of finish is required.

Corrosion Resistance

The major differences in corrosion resistance occur within the alloy groups, particularly aluminum and
magnesium. Aluminum alloys vary according to chemical composition, particularly copper content. Magnesium
alloys vary with metal purity. The more resistant alloys offer moderate corrosion resistance. The corrosion
resistance of all die casting alloys can be improved, as required, with a variety of low-cost surface treatment
systems.
ALLOY SELECTION

Bearing Properties & Wear Resistance

All die castings alloys can be used for hydrodynamic bearing applications, where oil is fed to the bearing under
pressure, and a full oil film is maintained by rotation of the journal in the bearing. Where only partial lubrication
is available, the ZA alloys and 390 aluminum offer very good resistance to abrasion and wear.
ALLOY SELECTION

Bearing Properties & Wear Resistance

All die castings alloys can be used for hydrodynamic bearing applications, where oil is fed to the bearing under
pressure, and a full oil film is maintained by rotation of the journal in the bearing. Where only partial lubrication
is available, the ZA alloys and 390 aluminum offer very good resistance to abrasion and wear.

Machinability
Die casting alloys offer good to excellent machining characteristics when machining operations are required.
Aluminum alloys exhibit moderate variation. Magnesium offers the best machinability of any structural metal in
terms of tool life, minimum energy consumption, and low cutting forces. In some cases, deep finish cuts are
made on magnesium alloys that would require two cuts (rough and finish) on any other alloy.
Different Types of Alloys
Different Types of Alloys
1. Aluminum Alloys

2. Nickel Alloys

3. Stainless Steel Products

4. Gold Alloys
Different Types of Alloys
1. Aluminum Alloys
Although Aluminum alone isn’t the strongest metal, it is used in combination with other metals to create
conductive, heat and tarnish resistant alloys. Aluminum is used in many essential mechanical components
including car engines, airplane body panels, and boat hulls.

2. Nickel Alloys
When Nickel and other metals come in contact with specific chemicals, they react in a way that produces
electricity. This process has been harnessed in batteries worldwide and continuing research in the field has
lead to the promise of electric cars.

3. Stainless Steel Products

All steel alloys are actually made from iron and and carbon. The carbon prevents the iron from oxidizing.
Chromium and Nickel are added as well to produce stainless steel. There are four classes of alloy steel:
structural steels, magnetic alloys, tool and die steels, and heat-resisting stainless steels. Consumers are very
familiar with the last type since refrigerators, sinks, forks, knives, and my other products are made from
stainless steel.
Different Types of Alloys
1. Aluminum Alloys
Although Aluminum alone isn’t the strongest metal, it is used in combination with other metals to create
conductive, heat and tarnish resistant alloys. Aluminum is used in many essential mechanical components
including car engines, airplane body panels, and boat hulls.

2. Nickel Alloys
When Nickel and other metals come in contact with specific chemicals, they react in a way that produces
electricity. This process has been harnessed in batteries worldwide and continuing research in the field has
lead to the promise of electric cars.

3. Stainless Steel Products

All steel alloys are actually made from iron and and carbon. The carbon prevents the iron from oxidizing.
Chromium and Nickel are added as well to produce stainless steel. There are four classes of alloy steel:
structural steels, magnetic alloys, tool and die steels, and heat-resisting stainless steels. Consumers are very
familiar with the last type since refrigerators, sinks, forks, knives, and my other products are made from
stainless steel.
Different Types of Alloys
1. Aluminum Alloys
Although Aluminum alone isn’t the strongest metal, it is used in combination with other metals to create
conductive, heat and tarnish resistant alloys. Aluminum is used in many essential mechanical components
including car engines, airplane body panels, and boat hulls.

2. Nickel Alloys
When Nickel and other metals come in contact with specific chemicals, they react in a way that produces
electricity. This process has been harnessed in batteries worldwide and continuing research in the field has
lead to the promise of electric cars.

3. Stainless Steel Products

All steel alloys are actually made from iron and and carbon. The carbon prevents the iron from oxidizing.
Chromium and Nickel are added as well to produce stainless steel. There are four classes of alloy steel:
structural steels, magnetic alloys, tool and die steels, and heat-resisting stainless steels. Consumers are very
familiar with the last type since refrigerators, sinks, forks, knives, and my other products are made from
stainless steel.
Different Types of Alloys
1. Aluminum Alloys
Although Aluminum alone isn’t the strongest metal, it is used in combination with other metals to create
conductive, heat and tarnish resistant alloys. Aluminum is used in many essential mechanical components
including car engines, airplane body panels, and boat hulls.

2. Nickel Alloys
When Nickel and other metals come in contact with specific chemicals, they react in a way that produces
electricity. This process has been harnessed in batteries worldwide and continuing research in the field has
lead to the promise of electric cars.

3. Stainless Steel Products

All steel alloys are actually made from iron and and carbon. The carbon prevents the iron from oxidizing.
Chromium and Nickel are added as well to produce stainless steel. There are four classes of alloy steel:
structural steels, magnetic alloys, tool and die steels, and heat-resisting stainless steels. Consumers are very
familiar with the last type since refrigerators, sinks, forks, knives, and my other products are made from
stainless steel.
Different Types of Alloys

4. Gold Alloys
Many different types of jewelry that’s ‘gold’ isn’t actually pure gold, but actually an alloy. That’s because gold is
incredibly malleable, making it next to impossible to form durable jewelry with. Gold itself is used in
manufacturing electronics due to the same malleability and because it is electrically conductive.
Properties of Alloys