MRTCastings NotesForDesigners

Notes For Designers of
Non- Ferrous Castings

- 2020 Edition
Contents
02 Introduction
03 Selecting the Best Suited Casting Method for Your Component
04 Relative Advantages & Limitations Of Common Casting Processes
08 Aluminium Casting Alloy LM5
25 Zinc Pressure Die Casting Alloy ZL3
27 Aluminium-Zinc Foundry Alloy ZL8
33 Copper Alloy LG2 (GUNMETAL)
35 Copper Alloy PB2 (PHOSPHOR BRONZE)
37 Linear Dimensional Tolerances
38 Linear Tolerances for Dimensions Across the Parting Line
39 Linear Tolerances For Dimensions Affected By Loose Cores Or Moving Die Parts
41 Flatness Tolerances
42 Calculating Minimum Achievable Section Thickness
45 Minimum Machine Finish Allowances in mm
46 Heat Treatment of Aluminium Alloys
50 MRT Castings Ltd – 70 Years of Excellence

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 sincerely hope that you will find this booklet a useful reference source
over the years to come, and hope 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,

May 2020.
www.mrt-castings.co.uk E : general@mrt-castings.co.uk T : +44 (0) 1264 324021 F : +44 (0) 1264 333773 02
Selecting the Best Suited Casting
Method for Your Component
In order to select the most appropriate alloy in which to cast a component,
designers should first select the most appropriate casting method. This
decision is usually based on the anticipated production volumes of the
component. It can also be influenced by considerations of the required
dimensional accuracy and surface finish.
Once the most appropriate process has been selected, designers should
decide upon the alloy that has the mechanical and physical properties
most appropriate to the particular application, whilst also considering
whether the casting characteristics are appropriate to the chosen process.
The table will assist you to choose the process most appropriate to your
requirements, however it is often necessary to obtain quotations for more
than one process in order to decide which will be the most economic.
Sand Gravity High Pressure
Up to 25mm ± 1mm ± 0.4mm ± 0.1mm

Tolerances on Critical
Each Additional cm ± 0.39mm ± 0.02mm ± 0.016mm
Dimensions
Across Parting Line Ad. ± 1mm ± 0.25mm ± 0.12mm
On Inside Walls 2° 1° 1°
Minimum Taper
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
Poor Fair Good

Surface Finish
6.5-12.5 μ 4-10 μ 1.5 μ
Alloys Aluminium LM5 ●

commonly LM6 ● ● ●
LM9 ● ●
used in this
LM16 ● ●
form 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
Relative Advantages & Limitations
Of Common Casting Processes
Sand Casting
Sand casting offers the simplest medium for production of non-ferrous
castings, by pouring molten metal into a sand mould. This process is
chosen for the production of small numbers of castings, for complex
shape castings requiring intricate cores, or for large castings. Advantages
include low tooling costs, largest casting sizes achievable, very low gas
porosity is possible, and general versatility of the process is good.
Limitations include low casting rate, 3-5mm minimum wall thickness, poor
linear tolerance (e.g. 4mm/m), rough surface finish (6.5-12.5μm), and a
coarser grain size than gravity die castings.
Gravity Die Casting (permanent mould casting)

Gravity die castings are produced by pouring molten metal into permanent
cast-iron moulds. This process produces chill castings. The process has a
higher casting rate than sand casting, but the metal moulds are higher cost
than sand patterns.
Low gas porosity is possible, and fine grain sizes can be obtained. Less
finishing and polishing will be required than for sand castings. Gravity die
casting tends to produce the highest quality castings, however the accuracy
achievable is limited. Minimum wall thickness possible is c. 3-5mm.
Low Pressure Die Casting

Low pressure casting is a development of the permanent mould process, in
which the metal is introduced into the chill mould from below. Gas pressure
holds the metal in the die until it solidifies. As with high pressure die casting
the process requires complex machinery. It is repetitive, and may be
automated.
Production rates are fair, but not as good as high pressure. Minimum wall
thickness’ are as little as 2-3mm. It has high yields of over 90%, as runners
and risers are excluded, also reducing fettling and trimming costs. Pore-free
castings are obtainable. Machine size will limit the size of castings. Surface
finishing and minimum wall thickness’ are both better than gravity, but
poorer than high pressure.
High Pressure Die Casting
Pressure die casting is a repetitive process where identical parts are cast
at high production rates by injecting molten metal under pressure into a
metal die. Again, this process requires complex machinery.
High pressure die casting is ideally suited to high production rates, and
wall thickness’ can be as little as 1-2.5mm. It provides the best surface
finish 1.5μ, and a very fine grain surface can be obtained. Pressure die
castings have high strength in the as cast condition. Castings may be
quenched from the die. Machine size will limit casting size. Sound thick
sections are difficult to cast, and core configurations must be complex to
enable disassembly.
Castings may suffer from porosity, although evacuated chamber and

other techniques may reduce this, High startup costs are only reduced
by long casting runs, thus enabling low unit cost with a high volume
production. Castings cannot be fully heat treated.
Investment Casting
This casting method involves producing a “wax pattern” by injecting wax
or plastic into a pattern die. The pattern is attached to gating and runner
systems and this assembly is dipped in a hard setting refractory slurry that is
then cured. The pattern is melted out of the mould to leave an exact cavity.
The mould is heated to cure the refractory and to volatilize the remaining
pattern material. The moulds are baked and molten metal is poured into the
mould cavity. On solidification of the casting, the mould material is broken
away from the casting.
Comparison Table of Casting Characteristics
& Other Properties of Major Aluminium Alloys
ALLUMINIUM ALLOYS
LM5 LM6 LM9 LM16 LM24 LM25 LM27 LM31
Tensile Strength (N/mm2) 140-170 160-190 95-120 170 180 130-150 140 215
Elongation (%) 3 5 3-5 2 1.5 2 1 4
Brinell Hardness 50-70 50-55 75-85 85 85 55-65 70-85 70
Density (g/cm3) 2.65 2.65 2.68 2.70 2.79 2.68 2.75 2.81
Freezing Range (°C approx.) 642-580 575-565 575-550 620-550 580-520 615-550 605-525 615-570
Thermal Con (cal/cm2/cm/°C @ 25°C) 0.33 0.34 0.35 0.34 0.23 0.36 0.37 0.35
Electrical Con (% copper std @ 20°C) 31 37 38 39 24 39 27 35
Machinability E P F G G G G G
Corrosion Resistance E E G G F E G E
Electro Plating Suitability F (2) F (1) F (1) F (1) F F G F
Non Spark NO NO NO NO NO NO NO NO
Casting Characteristics - Sand F E G G F* E G G
Casting Characteristics - Gravity F E G G F E E F
Casting Characteristics - High Pressure F G * * E G G F
Material Cost (£GBP/Kg - Aug 2020) £2.12 £1.78 £1.77 £1.80 £1.44 £1.77 £1.59 £2.12
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
Comparison Table of Casting Characteristics &
Other Properties of Major Zinc & Cooper Alloys
ZINC ALLOYS COOPER ALLOYS
ZL3 ZL8 ZL12 ZL27 LG2 PB2
Tensile Strength (N/mm2) 241-238 374 276-380 310-440 200-270 220-310
Elongation (%) 10-16 6-10 3-7 3-11 13-25 5-15
Brinell Hardness 82-87 103 105-125 90-120 65-75 75-110
Density (g/cm3) 6.7 6.3 6.03 5.01 8.5 8.8
Freezing Range (ºC approx.) 387-382 404-375 430-380 490-380 1010-854 1000-831
Thermal Con (cal/cm2/cm/ºC @ 25ºC) 0.27 - 0.21 - - -
Electrical Con (% copper @ 20ºC) 26.9 27.7 25 28 15 9
Machinability E E E E E G
Corrosion Resistance E E E E E E
Electro Plating Suitability E G G F F F
Non Spark YES YES YES NO YES YES
Casting Characteristics - Sand G E E E E E
Casting Characteristics - Gravity G E E G F F
Casting Characteristics - High Pressure E G F F U U
Material Cost (£GBP/Kg - Aug 2020) £2.30 £2.30 £2.40 £2.30 £4.99 £6.20
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
Aluminium Casting Alloy LM5
This alloy conforms to BS 1490:1988 LM5.
Chemical Composition
% % %
Copper 0.1 max Magnesium 3.0-6.0 Silicon 0.3 max
Iron 0.6 max Manganese 0.3-0.7 Nickel 0.1 max
Zinc 0.1 max Lead 0.05 max Tin 0.05 max

Titanium 0.2 max Aluminium Remainder Others: each 0.05 max
Others: total 0.15 max
Mechanical Properties
Sand Cast Chill Cast
0.2% Proof Stress (N/mm2) 90-110 90-120
Tensile Strength (N/mm2) 140-170 170-280
Elongation (%) 3 5
Impact Resistance lzod (Nm) 7.9 12.6
Brinell Hardness 50-70 60-70
Modulus of Elasticity (x103 N/mm2) 71 71
Shear Strength (N/mm2) 140 -
Strength At Elevated Temperatures

Room temperature properties are largely maintained up to 200°C, but fall
rapidly above 300°C.
Physical Properties
Coefficient of Thermal Expansion (per°C @ 20-100°C) 0.000023
Thermal conductivity (cal/cm2/cm/°C @ 25°C) 0.33
Electrical conductivity (% copper standard @ 20°C) 31.0
Density (g/cm3) 2.65
Freezing range (°C) approx. 642-580
Machinability
LM5 machines very well and takes an excellent polish.
Corrosion Resistance Anodising

This alloy is highly resistant to corrosion under LM5 may be anodised by any of the more common
most conditions and is superior to all other processes. A transparent colourless-to-whitish
Aluminium alloys for marine use. film is obtained according to the process used, and
is suitable for decorative finishing.
Applications and General Notes

LM5 is used where very high resistance to corrosion from sea water or marine
atmospheres is required, for equipment used for the manufacture of foodstuffs, cooking
utensils and chemical plant, and for castings required to exhibit and maintain a surface
of high polish.
Applications include, for example, door furniture, car fittings and trim, and similar
castings where a colourless anodic film is required.
LM5 is mainly used for sand castings and, to a lesser extent, for gravity die castings, but
pressure die castings of a relatively simple shape have been made. LM5 is not heat-
treated.
% % %
Copper 0.1 max Magnesium 0.10 max Silicon 10.0-13.0
Iron 0.6 max Manganese 0.5 max Nickel 0.1 max

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 lzod (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 - -

Tensile strength and hardness decrease fairly regularly with increasing
temperature and become relatively poor at 250°C.
Physical Properties
Coefficient of Thermal Expansion (per °C @ 20-100°C) 0.000020
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.

LM6 exhibits excellent resistance to corrosion LM6 can be anodised by any of the common
under both ordinary atmospheric and marine processes, the resulting film ranging in colour from
conditions. For the severest conditions, this grey to dark brown.
property can be further enhanced by anodic
treatment.

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.
This alloy conforms to BS:1490 1988 LM9. Castings are standardised in
the as cast (M) condition, in the precipitation treated (TE) condition or in
the fully heat treated (TF) condition.
% % %
Copper 0.2 max Magnesium 0.2-0.6 Silicon 10.0-13.0

M Chill Cast TF Sand Cast TF Chill Cast TE Sand Cast TE Chill Cast
0.2% Proof Stress (N/mm2) 95-120 220-250 270-280 110-130 150-170
Tensile Strength (N/mm2) 190 240 295 170 230
Elongation (%) 3-5 0-1 0-1 1.5 2
Impact Resistance lzod (Nm) - 0.7 1.4 1.4 2
Brinell Hardness 75-85 95 110 70 85
Modulus of Elasticity (x103 N/mm2) - 71 71 71 71
Shear Strength (N/mm2) - 200 230 120 160

Tensile properties are unaffected by temperatures up to 150°C but
prolonged heating at temperatures significantly higher reduces the
strength. For example, the tensile strength of chill cast LM9-TF at 200°C
(after heating for 500h) is approximately half that at room temperature,
and only 25% of the original value at 250°C.
Physical Properties
Machinability
Very considerable tool wear occurs in machining this alloy, but there is not the same tendency to drag that occurs
with high Silicon alloys containing no other alloying elements, e.g. LM6.
Carbide-tipped tools with large rake angles and relatively low cutting speeds give good results. A cutting
lubricant and coolant should be employed.
Corrosion Resistance Heat Treatment Anodising

LM9 exhibits excellent LM9 can be anodised by any Heat Treatment produces high
resistance to corrosion under of the common processes, strength and hardness.
both ordinary atmospheric and the resulting protective film
marine conditions. ranging in colour from grey to
dark brown, depending on the
method employed.

LM9 alloy is used where the fluidity and corrosion resistance of LM6 are required with
high strength and hardness.
It is equally suitable for sand and gravity die casting and is extensively used for low
pressure castings, for cover plates and instrument cases. It is useful for electroplated
components. LM9 has poor weldability and brazeability.
This alloy conforms to BS 1490:1988 LM16. Castings are standardised
in the solution treated and naturally aged (TB) condition and in the fully
heat treated (TF) condition.
% % %
Copper 1.0-1.5 Magnesium 0.4-0.6 Silicon 4.5-5.5

TB Sand Cast TB Chill Cast TF Sand Cast TF Chill Cast
0.2% Proof Stress (N/mm2) 120-140 140-150 220-280 250-300
Tensile Strength (N/mm2) 170 230 230-290 280-329
Elongation (%) 2 3 0-1 0-2
Impact Resistance lzod (Nm) 1.4 2.7 1.0 1.4
Brinell Hardness 80 85 100 110
Modulus of Elasticity (x103 N/mm2) 71 71 71 71
Shear Strength (N/mm2) - - 200 235

LM16 retains its strength well, up to 200°C.
Physical Properties
Electrical conductivity (% copper standard @ 20°C) 39
Machinability
The heat-treated alloy has fairly good machining properties, but tools, which should preferably be of high speed
steel, must be kept sharp. A moderately high rate of tool wear may be expected. Liberal cutting lubricant should
be employed.

The alloy has fairly good Full heat treatment gives high A protective film, usually
resistance to corrosion under strength and hardness. greyish in colour, may be
atmospheric conditions. obtained by either the sulfuric
or chromic acid process.

LM16 alloy is used for water-cooled cylinder heads, valve bodies, water jackets,
cylinder blocks, fire hose couplings, air compressor pistons, fuel pump bodies, aircraft
supercharger covers and similar applications where leak-proof castings having the high
strength produced by heat treatment are required.
It is equally suitable for sand casting and for gravity die casting. LM16 has good
weldability.
% % %
Copper 3.0-4.0 Magnesium 0.3 max Silicon 7.5-9.5

Titanium 0.2 max Aluminium Remainder
Others: total 0.5max
Chill Cast Die Cast
0.2% Proof Stress (N/mm2) 100-120 150
Tensile Strength (N/mm2) 180 320
Elongation (%) 1.5 1-3
Impact Resistance lzod (Nm) - 3.4
Brinell Hardness 85 85
Shear Strength (N/mm2) - 185

Room temperature tensile strength is largely retained up to temperatures
in the order of 150°C, and approximately halved at 250°C. It should be
noted that other factors may restrict the use of die castings at elevated
temperatures.
Physical Properties
Machinability
Machining practice is similar to that for other Aluminium castings alloys containing Silicon. Whilst there is not the
tendency to drag associated with high silicon alloys such as LM6, tool wear is more rapid than in the case of alloys
containing relatively small amounts of Silicon.
The use of carbide-tipped tools is recommended but a good finish can be obtained with high speed tools. Lower
alloy steel tools may be used, provided they are frequently reground to maintain a sharp cutting edge. A cutting
lubricant and coolant should be employed.

Resistance to attack under normal atmospheric Anodising treatment by either the chromic or
conditions is similar to that of alloy LM4, i.e. fairly sulfuric acid process produces an anodic film
good. In marine atmospheres, or under other grey in colour. The surfaces of die castings are
severe conditions, castings should be protected by not generally suitable for decorative anodising.
painting. Anodising would be necessary if this alloy is for
use in a corrosive environment.

LM24 is essentially a pressure die casting alloy, for which it has excellent casting
characteristics and is generally a little simpler to die cast that the high Silicon
containing alloys.
Die castings in LM24 are suitable for most engineering applications and have an
advantage over an alloy such as LM6 when maximum mechanical properties are
required. In practice LM6 is preferred to LM24 only for die castings in which a high
resistance to corrosion is the primary requirement. LM24 has poor weldability and
brazeability.
For the vast majority of die castings, the alloys LM2 and LM24 are equally suitable.
Castings in LM24 are not usually heat treated.
This alloy conforms to BS 1490:1988 LM25. Castings are standardised
in the cast (M) condition, the precipitation treated (TE) condition, the
solution treated and stabilised (TB7) condition and the fully heat treated
(TF) condition.
% % %
Copper 0.20 max Magnesium 0.20-0.6 Silicon 6.5-7.5

LM25-M LM25-TE LM25-TB7 LM25-TF
Sand Chill Sand Chill Sand Chill Sand Chill
0.2% Proof Stress (N/mm2) 80-100 80-100 120-150 130-200 80-110 90-110 200-250 220-260
Tensile Strength (N/mm2) 130-150 160-200 150-180 190-250 160 230 230-280 280-320
Elongation (%) 2 3 1 2 2.5 5 - 2
Impact Resistance lzod (Nm) - - - - - - - -
Brinell Hardness 55-65 55-65 70-75 75-95 65-75 65-75 90-110 90-110
Modulus of Elasticity (x103 N/mm2) 71 71 71 71 71 71 71 71
Shear Strength (N/mm2) - - 140 - - - 180 250
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 200°C, 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 135°C. At 200°C 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 130°C, for extended periods of time.
Physical Properties
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.

Resistance to corrosive attack There are three common A protective anodic film can be
by sea water and marine heat treated conditions for obtained by either the sulfuric
atmospheres is high. this alloy: TE (precipitation or chromic acid process, but
treated), TB7 (solution treated the grey opaque character of
and stabilised, and TF (fully coatings of normal thickness
heat treated). precludes their colouring in
light shades for decorative
purposes.

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.
% % %
Copper 1.5-2.5 Magnesium 0.35 max Silicon 6.0-8.0

Sand Cast Chill Cast
0.2% Proof Stress (N/mm2) 80-90 90-110
Elongation (%) 1 2
Impact Resistance lzod (Nm) - -
Shear Strength (N/mm2) - -

LM27 retains a high proportion of its original room temperature strength
at moderately elevated temperatures. For short period exposure, the
tensile strength of chill castings is reduced by only 20% at 200°C and by
40% at 250°C. The reduction in proof stress is considerably less.
Physical Properties
Freezing range (C) approx. 605-525
Machinability
LM27 has fairly good machining characteristics and is similar in this respect to LM4-M. For the best results,
tungsten carbide tools are recommended. Liberal use of cutting lubricant and coolant is advised.

Resistance to attack This alloy is standardised in Treatment by the more
under normal atmospheric the as cast condition, but common processes produces
conditions is fairly good. it has been shown that the a protective surface with a
tensile properties may be greyish opaque film. Anodising
substantially increased by for decorative purposes is
appropriate heat treatment. generally impracticable for
the depth of anodic coating
required to ensure adequate
durability.

LM27 is a very versatile alloy and, with its excellent castability, is suitable for most
general purpose castings where moderate mechanical properties are desirable, such as
general engineering components, domestic and office equipment, household fittings,
electrical tools and switch gear, automobile engine and transmission components.
It is equally suitable for sand and gravity die castings of thick or thin sections, and for
castings required to be pressure tight. In short, it can be used with the advantage of
slightly superior castability for the all the kinds of application for which LM4 is used and
may be expected, in time, to supersede the older alloy.
This alloy conforms to BS 1490:1988 LM31. Castings are standardised in
the as cast (M) condition and in the precipitation treated (TE) condition.
% % %
Copper 0.1 max Magnesium 0.5-0.75 Silicon 0.25 max
Zinc 4.8-5.7 Lead 0.05 max Tin 0.05 max

Chromium 0.4-0.6
Castings in the as cast (M) condition must be naturally aged for 3 weeks
to determine the mechanical properties.
M Sand Cast TE Sand Cast
0.2% Proof Stress (N/mm2) 170 -
Elongation (%) 4 4
Impact Resistance lzod (Nm) 2.7-4.0 -
Brinell Hardness 70 -
Modulus of Elasticity (x103 N/mm2) 71 -
Shear Strength (N/mm2) 180 -

In comparison with the other Aluminium casting alloys, the strength of
LM31 at elevated temperatures is good.
Physical Properties
Machinability
LM31 has good machinability characteristics.
Corrosion Resistance Heat Treatment

This alloy has very good Good strength and toughness can be produced by natural or artificial
corrosion resistance. ageing after casting. Castings in the as cast (M) condition must be
naturally aged for 3 weeks before testing to determine the mechanical
properties.
The TE heat treatment condition provides artificial ageing. Using this

Anodising alloy avoids the risks of distortion and cracking on quenching after
solution heat treatment.
This alloy is suitable for clear or
colour (decorative) anodising..

LM31 has very good shock resistance and is suitable for shock resisting components. It
is used for general engineering castings, particularly large sand casting.
Zinc Pressure Die Casting Alloy ZL3
This alloy conforms to EN 1774 1997.
% % %
Aluminium 3.8-4.2 Magnesium 0.035-0.06 Zinc Remainder
Impurities
Iron 0.020 max Copper 0.03 max Lead 0.003 max

Cadmium 0.003 max Tin 0.00.1 max Nickel 0.001 max
Sodium 0.02 max
Tensile Strength at 20ºC (N/mm2) 283-241
Elongation at 20ºC (% in 2 inches) 10-16%
Brinell Hardness 82-87
Impact Strength at 20ºC (J) (unnotched samples) 56.9

The advantage of a comparatively low melting point which allows the
zinc alloys to be die cast to such close dimensional limits entails the
disadvantages that zinc alloys cannot be used at elevated temperatures.
In cases where the temperature is likely to be maintained for
considerable periods of time, the maximum temperature recommended
is 150°C for unstressed parts and 100°C when light stresses are involved.
Where zinc die castings are to operate under continual stress and
changes in dimensions are critical, creep data should be consulted.
Physical Properties
Thermal conductivity (C. G. S. @ 18°C) 0.27
Electrical conductivity (% IACS @ 20°C) 26
Density (g/cm3) 6.7
Machinability
This alloy has excellent machining characteristics that means fast, efficient machining and long tool life.
Therefore, unlike its competing materials, it is an ideal alloy for components requiring substantial or difficult
machining.

Castings in this alloy possess good resistance A process for anodising zinc and zinc alloy die
to corrosion. In general, their behaviour may be castings has been developed and is reported to
expected to resemble that of unalloyed zinc, and give excellent resistance to salt water and good
zinc alloy die castings may be used with confidence resistance to abrasion. The finish is available
wherever the latter is known to be satisfactory. only in matt light green, grey and brownish tints.
The treatment is covered by U.S. Government
specification MIL-A-81801.

This alloy is general purpose alloy and is primarily used for producing castings for a
variety of applications on a hot chamber pressure die casting machine. Its mechanical
and physical properties make it ideal for use in castings for the engineering and
automotive industry, household equipment and utensils, office equipment, builder’s
hardware, locks, toys, giftware, etc. It is easily machined, buffed, polished, lacquered
and electro-plated for decorative or functional purposes.
Aluminium-Zinc Foundry Alloy ZL8
% % %
Aluminium 8.2-8.8 Magnesium 0.02-0.03 Zinc Remainder
Copper 0.9-1.3
Impurities
Cadmium 0.005 max Tin 0.002 max Nickel 0.001 max

Silicon 0.035 max Iron 0.035max Lead 0.005max
Tensile Strength at 20ºC (N/mm2) 374
Elongation at 20ºC (% in 2 inches) 6-10
Brinell Hardness 103
Impact Strength at 20ºC (J) (unnotched samples) 42

Due to its low melting temperature this alloy is not recommended for
components whose service exceeds 100°C. In addition reference should
be made to ZA8 mechanical properties at elevated temperatures and the
alloy’s creep properties for continually stressed components.
Physical Properties
Thermal conductivity 114.7 W/mc
Electrical conductivity (% IACS @ 20°C) 27.7
Density (g/cm3) 6.3
Machinability
This alloy has excellent machining characteristics, which means fast, efficient machining and long tool life.
machining.

Castings in this alloy possess good corrosion A process for anodising zinc and zinc alloy die
resistance but weathering will turn the surface castings has been developed and is reported to
grey in colour, therefore, for decorative purposes give excellent resistance to salt water and good
it should be lacquered, plated or painted, and for resistance to abrasion. The finish is available
more corrosive environments chromating or zinc only in matt light green, grey and brownish tints.
anodising should be considered. The treatment is covered by U.S. Government

With a short freezing range and excellent fluidity during casting, this alloy is ideal for
thin wall components. These cover a whole range of applications from functional
components, because of its good tensile strength, hardness and pressure tightness, to
decorative thin wall components because of its ease of electro-plating and painting.
The mechanical properties shown above are for pressure diecast components but alloy
can also be gravity diecast.
% % %
Aluminium 10.8-11.5 Copper 0.5-1.2 Magnesium 0.02-0.03
Zinc Reminder
Impurities
Iron 0.05 max Lead 0.005 max Cadium 0.005 max

Tin 0.002 max Silicon 0.05 max
Sand Cast Gravity Cast
Tensile Strength at 20ºC 276-310 345-380
Elongation at 20ºC (% in 2 inches) 3-4 4-7
Impact Strength at 20ºC (J) (unnotched samples) 5.4-10.8 17.6

Due to its low melting temperature ZA12 is not recommended for
components whose service temperature exceeds 100°C. Strength
will decrease with an increase of temperature from 20°C. In addition
reference should be made to ZA12 mechanical properties at elevated
temperatures and to the alloy’s creep properties for continually stressed
components.
Physical Properties
Electrical conductivity (%IACS @ 200C) 25
Machinability
This alloy has excellent machining characteristics, which means fast, efficient machining and long tool life.
machining.

Castings in this alloy possess good corrosion A process for anodising zinc and zinc alloy die
resistance but weathering will turn the surface castings has been developed and is reported to
grey in colour, therefore, for decorative purposes give excellent resistance to salt water and good
it should be lacquered, plated or painted, and for resistance to abrasion. The finish is available
more corrosive environments chromating or zinc only in matt light green, grey and brownish tints.
anodising should be considered. The treatment is covered by U.S. Government

With its excellent mechanical and physical properties ZA12 has whole range of potential
applications from stressed functional components because of its high tensile strength,
hardness, bearing properties and pressure tightness, to purely decorative thin wall
components because of its ease of electro-plating and painting.
A significant advantage of this alloy is that it is non-sparking. This enables its use in
hazardous environments such as underground mining and petroleum plants.
% % %
Aluminium 25.5-28.0 Copper 2.0-2.5 Magnesium 0.012-0.02
Zinc Reminder
Impurities
Iron 0.07 max Lead 0.005 max Cadium 0.005 max

Tin 0.002 max Silicon 0.07 max
Sand Cast Heat Treated
Tensile Strength at 20ºC 400-440 310-324
Elongation at 20ºC (% in 2 inches) 3-6 8-11
Impact Strength at 20ºC (J) (unnotched samples) 14.9 25.7

ZA27 can be considered for applications whose service temperatures are
as high as 150°C. Reference should be made to the alloy’s mechanical
and physical properties at elevated temperatures. For continually
stressed applications, reference should be made to ZA27 creep
properties.
Physical Properties
Machinability
This alloy has excellent machining characteristics that means fast, efficient machining and long tool life. It is ideal
for components requiring substantial or difficult machining.

ZA27 has good corrosion Elongation properties can A process for anodising zinc
resistance but weathering be further improved by and zinc alloy die castings
will turn the surface grey in simple heat treatment of has been developed and is
colour, therefore, if required the castings. This treatment reported to give excellent
for decorative purposes, it is consists of 3 hours at 320°C resistance to salt water and
necessary to add a protective and furnace cooled. good resistance to abrasion.
coating such as lacquer or The finish is available only in
paint. For more corrosive matt light green, grey and
environments, zinc anodising brownish tints. The treatment
should be considered. is covered by U.S. Government

This alloy has a whole range of potential stressed and functional applications. The high
tensile properties of the alloy, coupled with its castability, enable the engineer to design
in strength but at the same time reduce the overall material content of competitive
materials. ZA27 has good bearing properties, and is very suitable for wear resistant
applications.
Copper Alloy LG2 (GUNMETAL)
This alloy conforms to BS 1400 LG2.
% % %
Tin 4.0-6.0 Zinc 4.0-6.0 Lead 4.0-6.0
Nickel 1.0 Copper Remainder
Chill Cast
Tensile Strength at 200C’ 185
Elongation (%) 12
Brinell Hardness 55-65
Modulus of Elasticity (lbf/m2 x 106) 11

Service at elevated temperatures is limited by resistance to gradual
deformation over prolonged periods of time and to oxidation. It is not
suitable for sustaining loads at temperatures exceeding 300°C
Physical Properties
Thermal conductivity (W/M°C) 71
Density (g/cm3) 8.8
Machinability
The machinability of LG2 is excellent. The high lead content gives fine turnings with light cutting load and very
good machining characteristics.
Corrosion Resistance
This alloy finds wide application where good corrosion resistance is required.

This alloy is a very useful all-round alloy and has been known for many years as ‘ounce’
metal and also as ‘red brass’.
Applications include bearings, for backings only and general application, pressure
castings (for normal temperatures up to 200lbs. p.s.i., and steam pressures up to
100lbs. p.s.i. up to 260°C), and pressure-tight castings. It also suits wide applications
for general castings where moderate strength, pressure tightness and good
machinability are required, for example fire equipment fittings, hose couplings, water
pump impellers and small gears.
Copper Alloy PB2 (PHOSPHOR BRONZE)
This alloy conforms to BS 1400 PB2.
% % %
Tin 11.0-13.0 Phosphorous 0.15 min Lead 0.5 max
Nickel 0.5 max Zin 0.3 max Copper Remainder
Impurities 0.15 max
Chill Cast
Tensile Strength at 20°C (N/mm2) 220-310
Elongation (%) 7
Brinell Hardness 69
Modulus of Elasticity (lbf/m2 x 106) 12

Service at elevated temperatures is limited by resistance to gradual
deformation over prolonged periods of time and to oxidation. It is not
suitable for sustaining loads at temperatures exceeding 300°C.
The mechanical properties shown above cannot be used as an indication

of performance at elevated temperatures.
Physical Properties
Coefficient of Thermal Expansion (per °C @ 0-250°C) 0.000018.3
Thermal conductivity (W/M°C 45
Density (g/cm3) 8.8
Machinability
Machinability is good, being a medium hardness alloy. This material gives short turnings.
Corrosion Resistance
This alloy finds wide application where good corrosion resistance is required.

General uses include unlined bearings for heavy compressive loads and shock, piston
rings, axle boxes, gear wheels, centrifugal castings, and castings that require good wear
resistance.
Linear Dimensional Tolerances
P/ A
L
A
Sand
Pressure Diecasting Gravity Diecasting
Casting
Lenght of Dimension A
Aluminium or Alluminium, Zinc
Aluminium Zinc
Zinc or Copper
Basic Tolerance up to 25mm ± 0.075 ± 0.05 ± 0.4 -
Basic Tolerance up to 150mm - - - ± 0.75
Additional Tolerance for each futher 25mm ± 0.4 ± 0.025 ± 0.05 ± 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.
Linear Tolerances for Dimensions
Across the Parting Line
B
B
Pressure Die Cast

Projected Area of Casting
Aluminium Alloy Zinc Alloy
Up to 150 cm2 ± 0.1mm ± 0.075mm
150 to 300 cm2 ± 0.125mm ± 0.1mm
300 to 600 cm2 ± 0.2mm ± 0.15mm
Strength
600 to 1200 cm2 At Elevated Temperatures
± 0.3mm ± 0.2mm
Gravity Die Cast Sand Cast

Up to 60 cm2 ± 0.25mm ± 0.5mm
60 to 300 cm2 ± 0.375mm ± 0.875mm
300 to 600 cm2 ± 0.5mm ± 1.125mm
Strength
± 0.625mm ± 1.5mm
1500 to 3000 cm2 ± 0.75mm ± 2.25mm
These tolerances must be provided in addition to the linear dimensional

tolerances where a dimension is affected by the parting line. They
apply to dimensions both parallel and perpendicular to the parting line.
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.
Linear Tolerances For Dimensions
Affected By Loose Cores Or
Moving Die Parts
These tolerances must be provided in addition to the linear dimensional
tolerances where a core or moving die part affects a dimension.
C
A
Core
Y
View in Direction of Arrow A
Pressure Die Cast
Up to 60 cm2 ± 0.125mm ± 0.1mm
60 to 120 cm2 ± 0.2mm ± 0.15mm
120 to 300 cm2 ± 0.3mm ± 0.2mm
Strength
± 0.375mm ± 0.3mm
Gravity Die Cast Sand Casting

Aluminium or Zinc Aluminium or Zinc
Aluminium Zinc
Alloy with Metal Alloy with Sand
or Copper Alloys
Core Core
Up to 60 cm2 ± 0.25mm ± 0.375mm ± 0.5mm
60 to 300 cm2 ± 0.375mm ± 0.625mm ± 0.875mm
300 to 600 cm2 ± 0.375mm ± 0.75mm ± 1.125mm
600 to 1500 cm2 ± 0.55mm ± 1.0mm ± 1.5mm
1500 to 3000 cm2 ± 0.8mm ± 1.5mm ± 2.25mm

level. Greater accuracy involving extra work or care in production should
be specified only when and where necessary.
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.
Total
Maximum Tolerance Maximum
Dimension Dimension
Datum
Pressure Diecasting
Maximum Dimension
Up to 75mm within 0.2
for each additional 25mm add 0.075
Gravity Diecasting
Maximum Dimension
Sand Casting
Maximum Dimension

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:
1. The fluidity of the chosen alloy

2. The metallurgical quality required
3. 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 & Zinc Sand Casting
0.28 7mm
0.26 6.5mm
0.24 6mm
0.22 5.5mm
0.2 5mm
0.18 4.5mm
0.16 4mm
0.14 3.5mm
0.12 3mm
0.1 2.5mm
51 02 04 08 0 160 320 620
Total Surface Area in Square Inches
Metal Thickness: Aluminium & Zinc Gravity Die Casting
0.24 6mm
0.22 5.5mm
0.2 5mm
0.18 4.5mm
0.16 4mm
0.14 3.5mm
0.12 3mm
0.1 2.5mm
51 02 04 08 0 160 320 620
Metal Thickness: Aluminium Pressure Die Castin g
0.1 2.5mm
0.09 2.25mm
0.08 2mm
0.07 1.75mm
0.06 1.5mm
0.05 1.25mm
0.04 1mm
0.03 0.5mm
0.02 0.25mm
0 0mm
10 20 40 80
Metal Thickness: Zinc Pressure Die Castin g

0.08 2mm
0.07 1.75mm
0.06 1.5mm
0.05 1.25mm
0.04 1mm
0.03 0.75mm
0.02 0.5mm
0.01 0.25mm
0 0
10 20 40 80
Metal Thickness: Copper Alloy Sand Castings
0.5
0.4
0.3
0.2
0.1
0
1 2 4 8 16 32 64 128 256
Minimum Machine Finish
Allowances in mm
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 Gravity Diecast with
Sand Cast Gravity Diecast Pressure Diecas
Dimension Sand Cores
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.
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.
Heat Treatment of Zinc Alloys

Zinc alloys are not generally heat-treated, but annealing of ZA27 alloy
considerably improves ductility.
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, bur 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.
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.
Electroplating
Electroplating is a process which is used extensively on Zinc and Copper
alloy castings, and to a more limited extent on Aluminium castings, mostly
for decorative purposes. The coatings used include Copper, Nickel, Zinc,
Chromium, Silver and Gold. A high degree of surface
soundness is required.
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 diecasting in Aluminium and Zinc Alloys
• Gravity diecasting in Aluminium and Zinc Alloys including production of sand-cores
• Sand casting
• Heat Treatment
• Vibratory finishing and fettling
• CNC Turning, Milling, Drilling & Tapping
• Painting, Silk Screen Printing, Alochroming, Anodising and other surface finishing processes
• Electro-Mechanical Assembly
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. We look forward to being of service, and trust that
you have found this booklet useful and informative.

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Notes For Designers of

Non- Ferrous Castings

03 Selecting the Best Suited Casting Method for Your Component

04 Relative Advantages & Limitations Of Common Casting Processes

08 Aluminium Casting Alloy LM5

10 Aluminium Casting Alloy LM6

12 Aluminium Casting Alloy LM9

14 Aluminium Casting Alloy LM16

16 Aluminium Casting Alloy LM24

18 Aluminium Casting Alloy LM25

21 Aluminium Casting Alloy LM27

23 Aluminium Casting Alloy LM31

25 Zinc Pressure Die Casting Alloy ZL3

27 Aluminium-Zinc Foundry Alloy ZL8

29 Aluminium-Zinc Foundry Alloy ZL12

31 Aluminium-Zinc Foundry Alloy ZL27

33 Copper Alloy LG2 (GUNMETAL)

35 Copper Alloy PB2 (PHOSPHOR BRONZE)

37 Linear Dimensional Tolerances

38 Linear Tolerances for Dimensions Across the Parting Line

42 Calculating Minimum Achievable Section Thickness

45 Minimum Machine Finish Allowances in mm

46 Heat Treatment of Aluminium Alloys

50 MRT Castings Ltd – 70 Years of Excellence

Our technical advice is

©MRT Castings Limited,

Sand Gravity High Pressure

Up to 25mm ± 1mm ± 0.4mm ± 0.1mm

Minimum Wall On Small Castings 3mm 3mm 1mm

Minimum Size of Cored Hole 15mm 3mm 2mm

Ability to use Sand Cores Yes Yes No

Poor Fair Good

Alloys Aluminium LM5 ●

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

Gravity Die Casting (permanent mould casting)

Low Pressure Die Casting

Castings may suffer from porosity, although evacuated chamber and

LM5 LM6 LM9 LM16 LM24 LM25 LM27 LM31

Elongation (%) 3 5 3-5 2 1.5 2 1 4

Brinell Hardness 50-70 50-55 75-85 85 85 55-65 70-85 70

Electrical Con (% copper std @ 20°C) 31 37 38 39 24 39 27 35

Electro Plating Suitability F (2) F (1) F (1) F (1) F F G F

Casting Characteristics - Sand F E G G F* E G G

Casting Characteristics - Gravity F E G G F E E F

Casting Characteristics - High Pressure F G * * E G G F

ZINC ALLOYS COOPER ALLOYS

ZL3 ZL8 ZL12 ZL27 LG2 PB2

Tensile Strength (N/mm2) 241-238 374 276-380 310-440 200-270 220-310

Elongation (%) 10-16 6-10 3-7 3-11 13-25 5-15

Brinell Hardness 82-87 103 105-125 90-120 65-75 75-110

Density (g/cm3) 6.7 6.3 6.03 5.01 8.5 8.8

Thermal Con (cal/cm2/cm/ºC @ 25ºC) 0.27 - 0.21 - - -

Electrical Con (% copper @ 20ºC) 26.9 27.7 25 28 15 9

Electro Plating Suitability E G G F F F

Non Spark YES YES YES NO YES YES

Casting Characteristics - Sand G E E E E E

Casting Characteristics - Gravity G E E G F F

Casting Characteristics - High Pressure E G F F U U

Zinc 0.1 max Lead 0.05 max Tin 0.05 max

Others: total 0.15 max

0.2% Proof Stress (N/mm2) 90-110 90-120

Tensile Strength (N/mm2) 140-170 170-280

Impact Resistance lzod (Nm) 7.9 12.6