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Casting Terminology
Alloy Specifications
Aluminum


Although a variety of aluminum alloys made from primary or recycled metal can be die cast, most designers select standard alloys listed below:

Chemical Composition Charts

Commercial ANSI/AA Aluminum Die Casting Alloys
360
380
384
413
Detailed Composition
Silicon  (Si) 9.0-10.0 7.5-9.5 10.5-12 11.0-13.0
Iron (Fe) 2.0 2.0 1.3 2.0
Copper (Cu) 0.6 3.0-4.0 3.0-4.5 1.0
Magnesium   (Mg) 0.4-0.6 0.10 0.10 0.10
Manganese (Mn) 0.35 0.50 0.50 0.35
Nickel  (Ni) 0.50 0.50 0.50 0.50
Zinc (Zn) 0.50 3.0 3.0 0.50
Tin  (Sm) 0.15 0.35 0.35 0.15
Total Others   0.25 0.50 0.50 0.25
Aluminum  (Al) Balance Balance Balance Balance

* Single value indicates maximum

** All values are percentage by weight


Typical Material Properties
Commercial  ANSI/AA Aluminum Die Casting Alloys
360
380
384
413
Mechanical Properties
Ultimate Tensile Strength ksi (MPa) 44 (303) 46 (317) 48 (330) 43 (300)

Yield Strength

ksi (MPa)

25 (170) 23 (160) 24 (165) 21 (140)

Elongation 

% in 2in. (51mm)

2.5 3.5 2.5 2.5
Hardness BHN 75 80 85 80

Shear Strength 

ksi (MPa)

28 (190) 28 (190) 29(200) 25 (170)

Impact Strength

ft-lb

- - 3 (4) -
Fatigue Strength ksi (MPa) 20 (140) 20 (140) 20 (140) 19 (130)

Young’s Modulus  

psi x 10 6(GPa)

10.3  (71) 10.3  (71) - 10.3  (71)
Physical Properties

Density

lb / in³

(g/cm³)

0.095
(2.63)

0.099

(2.74)

0.102
(2.82)
0.096
(2.66)

Melting Range

°F

(°C)

1035-1105 (557-596) 1000-1100 (540-595) 960-1080 (516-582) 1065-1080 (574-582)

Specific Heat

BTU / lb °F

(J/kg °C)

0.23
(963)
0.23
(963)
0.23
(963)
0.23
(963)

Coefficient of Thermal Expansion 

µ in / in°F

µ m / m°K

11.6
(21.0)
12.2
(22.0)
11.6
(21.0)
11.3
(20.4)

Thermal Conductivity BTU / ft hr°F

(W / m °K)

65.3
(113)
55.6
(96.2)
55.6
(96.2)
70.1
(121)

Electrical Conductivity

% IACS

30 27 22 31
Poisson’s Ration 0.33 0.33 - -


Commercial  ANSI/AA Aluminum Die Casting Alloys
360
380
384
413
Resistance to Hot Cracking (a) 1 2 2 1
Pressure Tightness 2 2 2 1
Die-Filling Capacity (b) 3 2 1 1
Anti-Soldering to the Die (c) 2 1 2 1
Corrosion Resistance (d) 2 4 5 2
Machining Easy & Quality (e) 3 3 3 4
Polishing Ease & Quality (f) 3 3 3 5
Electroplating Ease & Quality (g) 2 1 2 3
Anodizing (Appearance) (h) 3 3 4 5
Chemical Oxide Protective Coating (i) 3 4 5 3
Strength at Elevated Temp. (j) 1 3 2 3

(a) Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature ranges.
(b) Ability of molten alloy to flow readily in die and fill thin sections.
(c) Ability of molten alloy to flow without sticking to the die surfaces. Ratings given for anti-soldering are based on nominal iron compositions of approximately 1%.
(d) Based on resistance of alloy in standard type slat spray test.
(e) Composite rating based on ease of cutting, chip characteristics, quality of finish, and tool life.
(f) Composite rating based on ease and speed of polishing and quality of finish provided by typical polishing procedure.
(g) Ability of the die casting to take and hold an electroplate applied by present standard.
(h) Rated on lightness of color, brightness, and uniformity of clear anodized coating applied in sulphuric acid electrolyte.
(i) Rated on combined resistance of coating and prolonged heating at testing temperature.

1= Most Desirable

5 = Least Desirable


360 - Selected for best corrosion resistance. Special alloys for special applications are available, but their use usually entails significant cost premiums.

380 - An alloy which provides the best combination of utility and cost.  Approximately 95% of aluminum die castings are produced from 380 Aluminum.

383 & 384 -
These alloys are a modification of 380. Both provide better die filling, but with a moderate sacrifice in mechanical properties, such as toughness.

413 (A13) -
Used for maximum pressure tightness and fluidity.

Cadmium-Free Anodes
 
 
 
 
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