1

Casting Guidelines
for LM6
Aluminium Alloy
 2

General Introduction

Potential and existing customers often ask, “Which material should be used
for this component?” “Can we anodise this alloy?” “What tolerance can
reasonably be achieved on these dimensions?” We have attempted to collate
the answers to these and many other questions.

The notes are for guidance. If, for example, a particular dimension requires to
be held within a closer tolerance than recommended here, it can often be
achieved. When the initial questions have been answered and further
information is required, we will be pleased to pass on the benefit of our
experience to enable best advantage to be made of the processes we offer.

We hope that you will find this booklet a useful reference source, and that
when you are seeking a quality supplier of cast components you chose MRT
Castings to work as a member of your team.

Our technical advice is given to the best of our knowledge, but without warranty.

MRT Castings Limited, March 2016.

 3

Introduction to LM6 Chemical Composition

Having high resistance to corrosion and Content Percentage (%)

excellent castability, aluminium alloy LM6 is
Aluminium Remainder
suitable for most marine castings, motor
vehicle and road transport fittings, intricate and Silicon 10 – 13

thin castings such as motor housings, meter Iron 0.6

cases and switch boxes, for large aluminium
Manganese 0.5
castings, e.g. cast doors and panels, for
chemical and dye industry castings, e.g. pump Titanium 0.2
parts, and for paint industry and food and
Magnesium 0.1
domestic castings. It is especially suitable for
castings that are to be welded. Copper 0.1

Others: Total 0.15

The ductility of LM6 enables castings to be
Zinc 0.1
rectified easily or even modified in shape, e.g.
simple components may be cast straight and Lead 0.1
later bent to the required contour.
Nickel 0.1

It has excellent resistance to corrosion in Tin 0.05

marine environments, possesses excellent Others: Each 0.05
ductility, but is of medium strength and is not
heat treated. Its strength falls off rapidly at high
temperatures. Its elastic limit is low and there
is some difficulty with machining.
 4

Comparison Table of Common Casting Process Properties

Sand Gravity Pressure

Tolerances on Up to 25mm  1mm  0.4mm

 0.1mm
Critical Each Additional cm  0.39mm  0.02mm
Dimensions Across Parting Line Ad.  0.016mm
 1mm  0.25mm
 0.12mm

Minimum Taper On Inside Walls 2 1 1

On Outside Walls 2 1 0.5

Minimum Wall On Small Castings 3mm 3mm 1mm

Thickness On Large Castings 5mm 4mm 2mm

Minimum Size of Cored Hole 15mm 3mm 2mm

Ability to use Sand Cores Yes Yes No

Surface Finish Poor Fair Good

6.5-12.5  4-10 
1.5 

Alloys Aluminium LM5 

commonly LM6   
used in this LM9  
form LM16  
LM24 
LM25  
LM27  
LM31 
Zinc ZA3  
ZA8 
ZA12  
ZA27  
Copper LG2 
PB2 

Typical Production Quantities per annum 1-500 250-50000 2000-500000

Typical Tool Life 5,000 100,000 500,000

 5

Comparison Table of Casting Characteristics & Other Properties of Major Non-Ferrous Alloys

ALLUMINIUM ALLOYS ZINC ALLOYS COPPER

ALLOYS

LM5 LM6 LM9 LM16 LM24 LM25 LM27 LM31 ZL3 ZL8 ZL12 ZL27 LG2 PB2
140- 160- 95- 130- 241- 276- 310- 200- 220-
Tensile Strength (N/mm2) 170 180 140 215 374
170 190 120 150 238 380 440 270 310
Elongation (%) 3 5 3-5 2 1.5 2 1 4 10-16 6-10 3-7 3-11 13-25 5-15
105- 90- 75-
Brinell Hardness 50-70 50-55 75-85 85 85 55-65 70-85 70 82-87 103 65-75
125 120 110
Density (g/cm3) 2.65 2.65 2.68 2.70 2.79 2.68 2.75 2.81 6.7 6.3 6.03 5.01 8.5 8.8
642- 575- 575- 620- 580- 615- 605- 615- 387- 404- 430- 490- 1010- 1000-
Freezing range (C approx.)
580 565 550 550 520 550 525 570 382 375 380 380 854 831
0
Thermal Con (cal/cm2/cm/C @ 25 C) 0.33 0.34 0.35 0.34 0.23 0.36 0.37 0.35 0.27 0.21
0
Electrical Con (% copper std. @ 20 C) 31 37 38 39 24 39 27 35 26.9 27.7 25 28 15 9
Machinability E P F G G G G G E E E E E G
Corrosion Resistance E E G G F E G E E E E E E E
Electro Plating Suitability F (2) F (1) F (1) F (1) F F G F E G G F F F
Non Spark NO NO NO NO NO NO NO NO YES YES YES NO YES YES
Casting Characteristics - Sand F E G G F* E G G G E E E E E
Casting Characteristics - Gravity F E G G F E E F G E E G F F
Casting Characteristics - High Pressure F G * * E G G F E G F F U U
Material Cost (pence/100 cc – October 2010) 60 53 53 54 50 53 50 64 132 127 124 105 439 617

E = Excellent
G = Good
F = Fair
P = Poor
U = Unsuitable
* = Not normally used in this form
1 = These alloys, containing Silicon, require a modification treatment for good adhesion
2 = Can be plated, but not recommended
 7

Aluminium-Silicon Casting Alloy LM6

This alloy conforms to BS 1490:1988 LM6

Mechanical Properties

Sand cast Die cast Chill cast

0.2% Proof Stress (N/mm2) 60-70 120 70-80

Tensile Strength (N/mm2) 160-190 280 190-230

Elongation (%) 5 2-5 7

Impact Resistance Izod (Nm) 6.0 - 9.0

Brinell Hardness 50-55 55-60 55-60

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

Shear Strength (N/mm2) 120 - -

Strength at Elevated Temperatures

Tensile strength and hardness decrease fairly regularly with increasing temperature and become
relatively poor at 250C.

Physical Properties

Coefficient of Thermal Expansion (per C @ 20-1000C) 0.000020

Thermal conductivity (cal/cm2/cm/C @ 250C) 0.34
Electrical conductivity (% copper standard @ 200C) 37
Density (g/cm3) 2.65
Freezing range (0C) approx. 575-565
 8

Machinability

Alloys of this and similar compositions are rather difficult to machine, due to their tendency to drag
and to the rapid tool wear caused by their high Silicon content. Carbide-tipped tools with large rake
angles and low cutting speeds give comparatively good results when cutting lubricant and coolant
are employed.

Corrosion Resistance

LM6 exhibits excellent resistance to corrosion under both ordinary atmospheric and marine
conditions. For the severest conditions, this property can be further enhanced by anodic treatment.

Anodising

LM6 can be anodised by any of the common processes, the resulting film ranging in colour from
grey to dark brown.

Application and General Notes

Having high resistance to corrosion and excellent castability, LM6 is suitable for most marine ‘on
deck’ castings, water-cooled manifolds and jackets, motor car and road transport fittings, thin
section and intricate castings such as motor housings, meter cases and switch boxes, for very large
castings, e.g. cast doors and panels where ease of casting is essential, for chemical and dye industry
castings, e.g. pump parts, and for paint industry and food and domestic castings. It is especially
suitable for castings that are to be welded.

The ductility of LM6 enables castings to be rectified easily or even modified in shape, e.g. simple
components may be cast straight and later bent to the required contour. LM6 is equally adaptable
for sand, gravity, and pressure die castings.

It has excellent resistance to corrosion in marine environments, possesses excellent ductility, but is
of medium strength and is not heat treated. Its strength falls off rapidly at high temperatures. Its
elastic limit is low and there is difficulty with machining.
 9

Closest Comparable Aluminium Alloys

Comparison Property Alloy

Tensile Strength (N/mm2) LM16, LM24

Elongation (%) LM9

Brinell Hardness LM25, LM5

Density (g/cm3) LM5

Freezing Range (C approx.) LM9

Thermal Con (cal/cm2/cm/C @250C) LM16

Electrical Con (% copper std. @ 200C) LM9

LM5, LM9, LM16, LM24, LM25,
Machinability
LM27, LM31
Corrosion Resistance LM5, LM25, LM31

Casting Characteristics – Sand LM25

Casting Characteristics – Gravity LM25, LM27

Casting Characteristics – High Pressure LM24, LM25, LM27, LM31

Material Cost LM9, LM25

 10

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.
 11

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

 12

Metal Thickness: Aluminium Gravity Die Castings

Metal Thickness: Aluminium Pressure Die Castings

 13

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 with Gravity Pressure
Dimension Sand Cores Diecast Diecast
less than 150mm 1.5 1.5 1.125 .0.375
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.
 14

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.
 15

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.
 16

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 9001:2015. Our ERP 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.