Magnesium Die Casting

Magnesium die casting is a manufacturing process used to produce components for automotive, aerospace, electronics, and power tool industries where weight reduction is critical. Parts are specified by dimensions, wall thickness, tolerances, and material grade, typically AZ91D or AM60B. Grades differ in alloying elements, affecting mechanical properties and corrosion resistance. The process involves injecting molten magnesium into a steel mold at high pressure, enabling thin walls and intricate geometries.

Typical parameters for magnesium die castings include wall thickness from 0.5 to 12 mm, dimensional tolerance of ±0.05 mm per ISO 8062-3, density of 1.8–1.9 g/cm³, tensile strength of 230–280 MPa, yield strength of 150–200 MPa, elongation at break of 2–10%, hardness of 60–90 HB, maximum operating temperature of 120–150°C, corrosion resistance of 48–96 hours salt spray per ASTM B117, surface roughness of 0.8–3.2 µm Ra, minimum draft angle of 0.5–1.0°, casting porosity of ≤5% per ASTM E505, heat treatment options T4, T5, T6, and machining allowance of 0.5–1.0 mm. These values are typical ranges and must be verified for specific applications.

Relevant standards include ASTM B94, ISO 16220, EN 1753, and GB/T 15114. These standards serve as procurement references; they do not imply certification of any specific product or supplier. When selecting a magnesium die casting, consider the required mechanical properties, corrosion resistance, operating temperature, and dimensional accuracy. Verify model-specific values and standards with the legal manufacturer or supplier.

Molten magnesium alloy is forced into a hardened steel die at high pressure (up to 1500 bar) and high speed, filling the cavity rapidly before solidification. The rapid cooling and pressure retain fine grain structure, yielding high strength and dimensional accuracy. After solidification, the die opens and the part is ejected, ready for trimming and finishing.