DIE CASTING ALLOYS

Die casting is a process for producing metallic parts, it is apparent that metallurgy must play an important part in the industry. In fact metallurgy along with mechanical engineering has been responsible for significant advancement in the process. Mechanical engineering has been responsible for the physical development of the process related to the casting mechanisms and the design and construction of dies, tools and other equipments. Metallurgy has been responsible for the derivation of suitable casting alloys for development of satisfactory methods for their preparations & control for advancements in methods of finishing the die cast parts. Since die casting are used in many types of products that functions under widely diversified conditions, it follows that die casting alloys, which is entirely satisfactory for one product of application may be entirely unsuitable for other. For e.g., the alloy for an automobile door handle is chosen primarily, to a low cost, adaptability to rapid casting cycles, satisfactory surface finish and amenability for plating. The casting alloy for a basis of strength and all other considerations are secondary importance. Hence a designer has first to select the most economical alloy on the basis of first cost & casting cost that will result in highest quality product. The pressure die casting process is nor applicable for casting of ferrous metals, since the machine parts as well as the die casting die parts are itself made up of ferrous metal and this cannot withstand the temperature of the molten ferrous metal, which is being injected. This means the pressure die casting dies is limited to non-ferrous material alloys having a melting point less than 900 degree centigrade. The alloys that can be die casted are of six types viz, Aluminium, Zinc, Magnesium, Copper, Lead & Tin. These are further classified in high fusion alloy & low fusion alloy. High Fusion Alloys The alloys having a melting point temperature more than 500 degrees come under this group, they are Al; Mg; & Cu alloys. Low Fusion Alloys The alloys having a melting point temperature less than 500 degrees fall under this group, & they are Zn; Sn; Pb alloys. The most commonly used alloys are, 1) Aluminium Alloys :LM-2; LM-4; LM-6; LM-24; Zinc Alloys :Mazak 3; Mazak 5 3) Magnesium Alloys:Mg-Al-91 & Mg-Al-911 4) Copper Based Alloys:A; B; & C Categories

2)

DESIRED PROPERTIES OF DIE CASTING ALLOYS

1) Good Mechanical Properties a. Tensile strength (Resistance to breaking under tension) b. Ductility (Can be easily molded) c. Hardness 2) Should have good dimensional stability 3) Should have low melting point 4) Less & Even shrinkage 5) Should be corrosion resistance & acidic resistance 6) Ability to take up finishing(Plating; Planishing) 7) Its adaptability to casting process (i.e.) cast ability & fluidity All the above properties are not found in single alloy. Selection of alloy depends on its suitability for the operation to perform.

ALUMINIUM ALLOYS
The chemical composition in % of various grades of Al alloys are, IS617 1959 A 2M A 4M A 6M A 8M BS 149 LM-2 LM-4 LM-6 LM-24 Cu 0.7-2.5 2.0-4.0 0.1 3.0-4.0 Si 9.0-11.4 4.0-6.0 10-13 7.5-9.5 Mg 0.3 0.15 0.10 0.10 Fe 1.0 0.8 0.6 0.3 Mn 0.5 0.3-0.7 0.5 0.5 Ni 1.0 0.3 9.1 0.5 Z n 1.2 0.5 0.1 1.0 Pb 9.3 0.1 0.1 0.3 Sn 0.3 0.005 0.1 0.2 Al rest rest rest rest

MECHANICAL & PHYSICAL PROPERTIES PROPERTY Brinell Hardness Tensile Strength Melting Point Solidification Point Casting Temperature Shrinkage Specific Gravity Density UNITS BHN Kg/mm^2 centigrade centigrade centigrade % Gms/cc LM2 65 22 595 570 660-720 0.6 2.7 LM4 75 24 616 520 640-700 0.6 2.71 LM6 80 26 580 570 630-710 0.6 2.65 LM24 80 27 585 525 650-720 0.6 2.75

or

ADVANTAGES OF AL ALLOYS Low density Good strength to weight ratio Comparatively high Tensile Strength Choice from number of alloys for a particular application Good dimensional stability Good machinability Good corrosion resistance Low raw material cost compared to pressed/ forged/ machined parts

 Good cast ability Can be easily plated & painted DISADVANTAGES Because of its high Melting Point, Die life is less as compared to Zn alloys

APPLICATIONS Automobile Parts Electrical Parts House Held Applications General Engineering Parts

ZINC ALLOYS
The chemical composition in % for various grades of Zinc alloys is as given below, Trade Name Mazak 3 Mazak --5 Al Cu Mg Fe Pb Cd Sn Zn

3.5-4.3 0.25-1.25 0.3-0.8 0.1 0.007 0.005 0.005 Rest 3.5-4.3 0.73-1.25 0.3-0.8 0.1 0.007 0.005 0.005 Rest

MECHANICAL AND PHYSICAL PROPERTIES:PROPERTY Brinell Hardness Tensile Strength Melting Point Solidification Point Casting Temperature Shrinkage Specific Gravity Density UNITS MAZAK MAZAK3 5 BHN 82 91 Kg/mm^2 28 32 centigrade 386.5 386.1 centigrade 380.6 380.4 centigrade 380-440 380-440 % 0.60-0.80 0.6 Gms/cc 6.6 6.7

or

ADVANTAGES OF ZINC ALLOYS: High Dimensional Stability High Cast ability Longer Die Life Can Take Up Very Good Surface Finish Good Machinability Low Melting Point

DISADVANTAGES OF ZINC ALLOYS:-

Weight is more Moderate corrosion & acidic resistance

APPLICATIONS: Machine parts Toys Automotive parts Pressure tight parts

MAGNESIUM ALLOYS
The chemical composition of Mg-Al alloys in % is as given below, Alloy Grade Mg-Al-91 Mg-Al-911 Al Zn Mn Si Cu Fe Mg Rest Rest

7.70-8.80 0.10-0.80 0.10-0.50 0.30 0.20 --7.6-10.0 0.10-1.0 0.10-0.50 0.40 0.35 0.0003-0.001

MECHANICAL PROPERTIES:PROPERTY Brinell Hardness Tensile Strength Melting Point Casting Temperature Shrinkage Specific Gravity Density UNITS Mg Al --91 BHN 55 Kg/mm^2 16-23 centigrade 599 centigrade 620-670 % 0.6 Gms/cc 1.8 Mg Al 911 55 15-22 599 620-670 0.6 1.82

or

ADVANTAGES OF Mg ALLOYS Light in weight (2/3 of the Al) Close dimensional tolerance is possible Excellent machinability Solidification time is shorter Good surface finish

DISADVANTAGES Highly inflammable Heeds very careful storing High melting point

Much care has to be taken while melting

APPLICATIONS Air craft industries Portable hand tools Camera parts

COPPER BASED ALLOYS

The chemical composition of Cu alloys in % is as given below, Alloy Grad e A B C D ADVANTAGES OF Cu ALLOYS Excellent Mechanical Properties Good Thermal & Electrical Properties Good Resistance to corrosion Cu 57.0 Min 63.0-67.0 80.0-83.0 Si 0.25 Max 0.751.25 3.754.25 Pb 1.50 Max 0.25 Max 0.15 Max Sn 1.50 Max 0.15 Max 0.25 Max Mn 0.25 Max 0.15 Max 0.15 Max Al 0.25 Max 0.15 Max 0.15 Max Fe Mg Zn 0.30 Min Rest Rest Others 0.50 Max --1.25

0.15 Max

0.50 Max 0.15 Max

DISADVANTAGES High melting point Die Life is short High Density Poor cast ability

APPLICATIONS Automobile gears Electrical equipments Pumps