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DIE CASTING ALLOYS

IMPORTANCE
(GOVERNING FACTORS FOR SELECTION)

Cost
Die life
Physical properties flowability, corrosion
resistance, wear resistance, etc.
Mechanical properties tensile strength,
hardness, elongation, impact strength, etc.
Thermo-phy. properties thermal expansion,
melting range, density, sp. heat capacity, etc.
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COST
Aluminium and Magnesium are abundant
but their extraction is a long process
making them costly.
Copper and Zinc are less abundant and are
less costly to extract. But their yield from
ore is less than 1% and in future we may
face problems in obtaining them.

DIE LIFE
Cold Chamber Process
There is less time exposure of the melt to the plunger
walls or the plunger. This is particularly uses metals
such as Aluminum and Copper that tend to easily alloy
with Iron at the higher temperatures.

Hot Chamber Process


The metals used for this process are of low melting
point and high fluidity such as Tin, Magnesium, Zinc,
and Lead that tend not to alloy easily with steel at their
melt temperatures.
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Alloys used in die casting have freezing ranges, from a


few degrees for the zinc alloys with 4% aluminum to over
a hundred degrees for magnesium alloys.
Alloys

Liquidous Solidous

Freezing
Range

Zinc alloy (4.1% AI)

387

382

8%Si 605

577

28

10%Si 590

577

13

11%Si 585

577

12%Si 582

577

520

60

Aluminum-silicon alloys

Aluminum-silicon
copper alloy
(10.5% Si, 3.5% Cu)

580

Aluminum-magnesium
alloys
5%Mg

635

590

45

7,5% Mg

625

560

65

10.0% Mg

610

525

85

596

468

128

Brass (60% Cu, 39.5% Zn,


910
0.5% AI)

900

10

Aluminum bronze
(89% Cu, 10% AI, 1% Fe)

1053

1040

13

Lead alloy (5% Sb)

310

270

40

Magnesium alloy (9% AI)