Complete

Guidelines for
Manufacture with
LM25 Alloys

© MRT Castings Limited 2017 | Registered in England - No. 3150165 | VAT No. GB 199 1318 33
 Contents
Introduction ............................................................................................................................. 1
Chemical Composition .......................................................................................................... 1
Mechanical Properties .......................................................................................................... 2
Strength at Elevated Temperatures ................................................................................. 3
Physical Properties ................................................................................................................ 3
Machinability ........................................................................................................................... 3
Corrosion Resistance............................................................................................................. 3
Anodising ................................................................................................................................... 3
Heat Treatment ....................................................................................................................... 4
Applications and General Notes ........................................................................................ 4
Comparable Aluminium Alloys .......................................................................................... 5
Flatness Tolerances ............................................................................................................. 6
Calculating Minimum Achievable Section Thickness............................................ 7
Metal Thickness: Aluminium Sand Castings ......................................................... 7
Metal Thickness: Aluminium Pressure Die Castings ............................................ 8
Machine Finish Allowances .............................................................................................. 9
Heat Treatment of Aluminium Alloys .......................................................................... 10
Mechanical Finishing ............................................................................................ 11
Alochroming .......................................................................................................... 11
Powder Coating, Painting, Silk Screen Printing & Enamelling........................... 11
Anodising............................................................................................................... 12
MRT CASTINGS LTD - 70 Years of Excellence ....................................................... 12

© MRT Castings Limited 2017 | Registered in England - No. 3150165 | VAT No. GB 199 1318 33
 Introduction
MRT manufactures gravity die castings, Chemical Composition
sand castings and high pressure die
castings in LM25 Aluminium Alloy. Content Percentage (%)

Aluminium Remainder
One of the greatest benefits of selecting
LM25 is the strength that can be Silicon 6.5 – 7.5
achieved in the heat treated condition.
Magnesium 0.2 – 0.6

However, heat treatment cannot normally Iron 0.5

be used on high pressure die castings,
Manganese 0.3
meaning that LM25 is most commonly
used for gravity or sand casting. Copper 0.2

Titanium 0.2
This alloy conforms to BS 1490:1988
LM25. Others: Total 0.15

Zinc 0.1
Castings are standardised in the
following conditions: Lead 0.1
- Cast (M)
Nickel 0.1
- Precipitation Treated (TE)
- Solution Treated & Stabilised Tin 0.05
(TB7)
Others: Each 0.05
- Fully Heat Treated (TF)

© MRT Castings Limited 2017 | Registered in England - No. 3150165 | VAT No. GB 199 1318 33
 Mechanical Properties

LM25-M LM25-TE LM25-TB7 LM25-TF

Sand Chill Sand Chill Sand Chill Sand Chill

0.2% Proof 220-

80-100 80-100 120-150 130-200 80-110 90-110 200-250
Stress (N/mm2) 260

Tensile Strength 280-

130-150 160-200 150-180 190-250 160 230 230-280
(N/mm2) 320

Elongation (%) 2 3 1 2 2.5 5 - 2

Brinell Hardness 55-65 55-65 70-75 75-95 65-75 65-75 90-110 90-110

Modulus of
Elasticity (x103 71 71 71 71 71 71 71 71
N/mm2)

Shear Strength
- - 140 - - - 180 250
(N/mm2)
Strength at Elevated Temperatures
The tensile properties of LM25 alloy at elevated temperatures are influenced by the
condition (heat treatment) of the castings and the duration at the elevated temperature.

On short term testing e.g. 30 minutes at temperature, the properties fall only slowly and
uniformly up to about 200C, at which temperature the strength of LM25-TF is reduced
by about 20%.

Very prolonged heating, e.g. 10,000 hours, results in a sharp loss of strength at about
135c. At 200c the strength of LM25-TF is less than half of that at room temperature.
There is therefore no advantage to be gained by heat treatment, if the component is to
be used at temperatures above about 130C, for extended periods of time.

Physical Properties
Coefficient of Thermal Expansion (per C @ 20-100C) 0.000022
Thermal conductivity (cal/cm2/cm/C @ 25C) 0.36
Electrical conductivity (% copper standard @ 20C) 39
Density (g/cm3) 2.68
Freezing range (C) approx. 615-550

Machinability
The heat-treated alloy has fairly good machining properties, but tools should preferably
be of high speed steel and must be kept sharp. A moderately high rate of tool wear
may be expected. Liberal cutting lubricant should be employed.

Corrosion Resistance
Resistance to corrosive attack by sea water and marine atmospheres is high.

Anodising
A protective anodic film can be obtained by either the sulphuric or chromic acid process,
but the grey opaque character of coatings of normal thickness precludes their colouring
in light shades for decorative purposes.
Heat Treatment
There are three common heat treated conditions for this alloy: TE (precipitation treated),
TB7 (solution treated and stabilised, and TF (fully heat treated).

Applications and General Notes

LM25 is mainly used where good mechanical properties are required in castings of
shape or dimensions requiring an alloy of excellent castability in order to achieve the
desired standard of soundness.

The alloy is also used where resistance to corrosion is an important consideration,

particularly where high strength is also required. It has good weldability.

Consequently, LM25 finds application in the food, chemical, marine, electrical and many
other industries and, above all, in road transport vehicles where it is used for wheels,
cylinder blocks and heads, and other engine and body castings. Its potential uses are
increased by its availability in four conditions of heat treatment in both sand and chill
castings.
It is, in practice, the general purpose high strength casting alloy, whose range of uses is
increased by its availability in the as-cast and partially heat-treated condition as well.

It is used in nuclear energy installations and for aircraft pump parts.

LM25 may be superior for castings, particularly in chill moulds, which are difficult to
make to the required standard of soundness. It offers better machinability and
mechanical properties than LM6.
Comparable Aluminium Alloys

Comparison Property Alloy

Tensile Strength (N/mm2) LM27

Elongation (%) LM16

Brinell Hardness LM5

Density (g/cm3) LM9

Freezing Range (C approx.) LM31

Thermal Con (cal/cm2/cm/C @25C) LM27, LM9

Electrical Con (% copper std. @ 20C) LM16

Machinability LM5, LM16, LM24, LM27, LM31

Corrosion Resistance LM5, LM6, LM31

Casting Characteristics – Sand LM6

Casting Characteristics – Gravity LM6, LM27

Casting Characteristics – High Pressure LM27

Material Cost LM6, LM9

Flatness Tolerances
The flatness of a casting can be measured by supporting the surface in question on
three widely separated points to establish a datum and measuring the deviation from
that plane by the use of feeler gauges. The flatness tolerance is the total deviation
permitted from the datum and consists of the distance between two parallel planes
within which the entire surface so tolerated must lie.

Pressure Diecasting
Maximum Dimension
Up to 75mm within 0.2
for each additional 25mm add 0.075
Gravity Diecasting
Maximum Dimension
Up to 150mm within 0.5
for each additional 25mm add 0.075
Sand Casting
Maximum Dimension
Up to 150mm within 0.75
for each additional 25mm add 0.075
The values shown represent production practice at the most economical level. Greater
accuracy involving extra work or care in production should be specified only when and
where necessary.
Calculating Minimum Achievable Section Thickness

The minimum section thickness which can be cast is proportional to the total surface
area. However, other factors must be taken into consideration, including:

 The fluidity of the chosen alloy

 The metallurgical quality required
 The complexity of the casting

Where minimum sections are specified, particular attention must be paid to radii, taper,
tolerances and changes of section.

Metal Thickness: Aluminium Sand Castings

Metal Thickness: Aluminium Gravity Die Castings

Metal Thickness: Aluminium Pressure Die Castings

Machine Finish Allowances

It is always advisable to discuss with the Foundry the method of machining and the
locations to be used as datums for each operation. As will be seen on the notes
regarding tolerances, the dimensional relationship between different areas on a casting
varies according to the die and mould construction.

The need for machinist and die-designer to co-operate cannot be over emphasised.
Frequently, the cost of finished castings can be significantly reduced by arranging for
casting feeders to be located on areas which are to be machined. This minimises the
need for fettling, and eliminates the feeder witnesses on the finished component.

Below is a table showing the amount of metal normally added for machining. The
amount of material to be added is related to the overall size of the casting, rather than
varying with individual dimensions. The designer should select that line on the table
below showing the range within which the casting’s greatest dimension falls.

Minimum Machine Finish Allowances in mm

Greatest Sand Cast Gravity Diecast Gravity Pressure
Dimension with Sand Cores Diecast Diecast
less than 1.5 1.5 1.125 .0.375
150mm
150-300mm 2.25 .2.25 .1.5 0.5
300-450mm 3.0 3.0 1.875 0.625
450-600mm 3.75 4.5 2.25 0.75

The values given in the above table are based on maximum ‘build-up’ or a ‘safety factor’
for average casting variations in flatness, squareness, concentricity, etc., as well as
linear tolerance. The values are the minimum recommended, and taper, when required,
must be added to the above values.
Heat Treatment of Aluminium Alloys
Most aluminium castings are used in the ‘as cast’ condition, but there are certain
applications that require higher mechanical properties, or different properties from the
as cast material.

The heat treatment of aluminium castings is carried out to change the properties of the
as cast alloys by subjecting the casting to a thermal cycle or series of thermal cycles.
For sand castings and gravity die castings all heat treatments are possible, though not
all are standardised. Pressure die castings however, cannot generally be heat treated.

The following are the suffixes used in the UK to indicate the heat treatment condition of
BS1490 Aluminium Alloys:
M As cast
TS Thermally stress relieved, annealed
TB Solution heat treated and naturally aged to a substantially stable condition
TB7 Solution heat treated and stabilised
TE Artificially aged
TF Solution heat treated and artificially aged
TF7 Solution heat treated, artificially aged and stabilised

The following alloys are not fully heat treated: LM0, LM2, LM5, LM6, LM20, & LM24.

The following alloys may be heat treated, but their properties are not standardised in
the heat treated condition shown: LM12, LM21, LM27-TF & LM30-TF.

The following alloys are standardised in the heat treated conditions indicated: LM4-TF,
LM9-TE, LM9-TF, LM13-TE, LM 13-TF, LM13- TF7, LM16-TB, LM16-TF, LM22-TB,
LM25-TE, LM25-TB7, LM25-TF, LM26-TE, LM28-TE, LM28-TF, LM29-TE, LM29-TF,
LM30-TS.

LM31 is a naturally ageing material, which may also be artificially aged.

Mechanical Finishing
There are a variety of mechanical finishing processes which can enhance the aesthetic
quality of castings, and in several cases these processes will also be used as a pre-
treatment if the casting requires subsequent painting.

For Sand castings, shotblasting is often used to remove sand, and to provide an even
surface finish whilst giving a good key for painting. In the case of Gravity and Pressure
die castings, Vibratory finishing is the most efficient method for cleaning the castings,
removing burrs and smoothing the surface. This provides a more pleasing casting
finish and again is a good preparation for subsequent painting.

To achieve a polished casting finish, a cheap and effective method is Ball Burnishing,
which is often used on aluminium cookware and window furniture. Polishing provides
an attractive finish for castings, but care must be taken in selecting alloys which have
corrosion resistance appropriate to their destination environment.

Alochroming
Alochroming is a treatment for Aluminium alloy castings, which involves immersion in
chemical baths, spraying or brushing, with a solution that chemically reacts with the
Aluminium to produce an etched surface or to form a chemically converted protective
film. It can also be used as a pre-treatment for painting. The chemical conversion
process gives decorative and corrosion resistant finishes, but for most applications they
are generally too easily abraded to be of practical use alone.

Powder Coating, Painting, Silk Screen Printing & Enamelling

High Bake Powder Coating is a low cost process for items requiring a high degree of
impact and abrasion resistance. The resulting finish is tough and durable, and is
available in varying levels of gloss and texture. It should however be borne in mind that
masking on items to be powder coated is difficult and time-consuming (hence costly),
and should be avoided if possible.
Small surface blemishes which are not easily detectable on raw castings become much
more noticeable after powder coating.

For higher levels of surface finish, wet sprayed coatings should be considered. Proper
surface pre-treatment and the application of a suitable primer such as Zinc Chromate is
essential if the final paint coating is to be truly protective.

Stove enamelling temperatures are not usually high enough or of sufficient duration to
influence the properties of Aluminium castings but should be taken into account with
fully heat treated castings. Where it is necessary to add lettering or other artwork to
painted castings, this can often be achieved by Silk Screen Printing.

Anodising
Anodising is an electrolytic process for producing a thick oxide coating on Aluminium.
Anodising takes advantage of the natural oxide film that is formed spontaneously on the
surface of Aluminium when exposed to the air. This natural oxide film, which is
extremely thin, protects the underlying metal, giving its well-known properties of
resistance to corrosion. With time the film will go grey in colour which is acceptable in
some applications, but not in situations which appearance is importance.

In aggressive atmospheres the film can become sooty, and sometimes even powdery.
Anodising thickens this oxide film electro-chemically to give a hard transparent coating,
which greatly increases corrosion resistance and has the advantage of protecting any
polished, chemically brightened, etched or similar surface finish. Unsealed anodic films
are microporous and can be dyed.

MRT CASTINGS LTD - 70 Years of Excellence

MRT is a family run business specialising in the supply of fully machined and finished
cast components. We believe that we are in a unique position to work with you to see
your designs through to production.
Our versatility and experience as founders and machinists of non-ferrous castings
allows us to offer a complete service, from assistance with component design, through
the early stages of tooling and prototype production, and on into the future with the
production of quality cast components.

Our services include –

 Assistance with component and tooling design

 Toolmaking and patternmaking
 Pressure die casting in Aluminium and Zinc Alloys
 Gravity die casting in Aluminium and Zinc Alloys
 Sand casting
 Heat Treatment
 Vibratory finishing and fettling
 CNC Turning, Milling, Drilling & Tapping
 Painting, Silk Screen Printing, Alochroming, Anodising and other surface
finishing processes

All of our services operate under the strictest quality standards. Our inspection facilities
include CNC Co-ordinate measuring. We are registered to ISO 9001:2008. Our
computerised management and production system ensures that we can work with you
to meet the demands of Total Quality Management and Just in Time production.

If you would like to discuss your project on a no-strings basis please contact our Sales
team, who will be happy to advise you on any design queries and costings.