Magnesium Die Casting

Inox Cast Magnesium Die Casting

Inox Cast is a professional and rich experience in a magnesium die casting. We have a full capability of die casting various magnesium steel alloys including AM50, AM60B, AZ91D, and more. At Inox Cast, we can surely provide your magnesium die casting solution.

We also offer magnesium die casting components and parts for various applications and industries. We provide magnesium die cast components for automotive, medical, plumbing, electrical, aerospace, machinery, and more. Inox Cast guarantees you a superior magnesium casting.

Benefits of Inox Cast Magnesium Die Casting

• 100% recyclable
• Light structural materials
• Good finishing characteristics
• Excellent stiffness
• Can withstand highest operating temperatures
• Excellent environmental corrosion resistance
• Perfect thin wall capability
• Superior RFI and EMI shielding properties

All our magnesium die casting processing is done through our in-house modern facility and advanced technology. We make sure that we are certified by ISO9001, CE, and other international quality standard regulations.

We serve industries such as power tools, electrical, medical, automotive, etc. Inox offers reliable quality magnesium die casting solution based on your requirements. Our magnesium die casting solution comes with competitive price, high-quality, and excellent services.

Inquire now!

Magnesium Die Casting: The Ultimate FAQ Guide

This is the process of forcing molten magnesium into a reusable mold to produce a metal cast.

The process will produce dimensionally accurate magnesium parts containing a smooth and flawless finish.

Magnesium die casting makes accurate parts making it suitable for mass production of magnesium die casts.

In this guide, we shall look at different characteristics of magnesium die casting.

Also, we shall look at the manufacturing processes among others.

Let’s dive right in:

What Are The Benefits Of Die Casting Magnesium?

An Engine Case Made From Magnesium Die Casting Process

There are several advantages of magnesium die casting and they include the following:

• A longer tool life
• Suitable finishing traits
• Magnesium is an easy alloy to machine
• It will provide suitable RFI shielding
• The scrap materials are 100% recyclable
• It also offers suitable EMI shielding
• Magnesium is a strong and lightweight material, 75% and 33% lighter than steel and aluminum respectively
• Also, it will offer suitable damping characteristics against vibration and noise
• It is suitable for complicated components
• Suitable resistance against environmental corrosion
• It offers the exceptional capability to thin walls
• High dimensional accuracy and high stability
• It can withstand very high operational temperatures
• Also, it offers high conductivity, thermal, and electrical characteristics
• It has a lower melting point than that of aluminum and solidifies at a fast rate than other metals
• Also, it has an excellent structure and the components have suitable mechanical characteristics
• The parts offer a suitable surface finish than metals such as aluminum and zinc

Are There Limitations Of Die Casting Magnesium?

The disadvantages include the following:

• Die casting magnesium do not have the stability that of aluminum or zinc
• Besides, they also need extensive post-production processes
• Also, it offers high production cost than zinc or aluminum die casting
• It is not easy producing large metal components when using magnesium die casting processes
• The components are prone to flaws like blisters, misrun, or porosity.

Which Parts Can You Make From Magnesium Die Casting?

There are several areas you can use magnesium die casting, such as:

• Accelerator brackets
• Seat risers
• Clutch brackets
• Keylock housing
• Glove box doors
• Mirror brackets
• Engine blocks
• Door handles
• Steering wheel
• Fuel filler lids
• Camera bases
• Oxygen concentrators
• Heat sinks
• Cell phone frames
• Seat frames
• Mirror brackets
• Console brackets
• Lens cover frames
• Engine cooling fans
• Racing wheels
• Electric motor housing, etc.

Parts Made From Magnesium Die Casting

How Strong Is Die Cast Magnesium?

Die cast magnesium is stiffer and stronger than other engineered plastics besides being lightweight.

Besides, they have high resistance against wear, high temperature, and impact.

Which Magnesium Die Cast Alloys Are Common?

The various alloys available for magnesium die casting include the following:

AZ91D Alloy

This is popular magnesium die cast alloy is suitable for high-pressure casting die.

Besides, this alloy has the benefits such as:

1. The strength-to-weight ratio is excellent
2. Good resistance to corrosion
3. Excellent castability

This alloy is suitable for making power trains and other mechanical parts where its toughness is vital than deformation traits.

AZ91D Alloy

AM60B Alloy

This alloy is suitable for casting safety parts for automotive such as seat frames and the instrument panel structure.

The benefits of this alloy include the following:

1. Suitable ductility
2. Excellent strength
3. Suitable energy absorbing traits
4. Excellent castability

 AM60B Alloy

AM50A Alloy

This type of magnesium alloy has a lower content of aluminum than AM60B alloy.

For this reason, it has high ductility besides having low strength and minimal castability.

This alloy is suitable in areas where the performance requires elongation characteristics greater than that of AM60B.

AS41B Alloy

This alloy has a high melting point and low thermal conductivity and tensile strength.

AM20 Alloy

This alloy has excellent ductility and high impact strength.

AZ91E-T6 Alloy

This is an example of cast magnesium alloy that has high strength.

It finds its application in areas requiring high tensile strength and medium yield strength.

AE42 Alloy

This alloy has good strength and the creep resistance is about 150 degrees Celcius.

AE44 Alloy

This alloy contains rare-earth materials such as cerium and lanthanum.

AJ62A Alloy

This alloy can withstand high temperatures.

WE43 Alloy

This is an alloy that finds its application in airplanes and high-performance cars.

It has good tensile strength.

WE43 Alloy Is Suitable In Aircraft Parts Manufacture

AZ31B Alloy

This is an example of a wrought magnesium alloy.

It offers benefits such as:

1. Suitable ductility and strength
2. Suitable corrosion resistance
3. Weldability
4. Good extrusion

AZ91 Alloy

This alloy is suitable for making die casting.

What Does Magnesium Die Casting Process Involve?

Magnesium die casting process varies a lot depending on what process the manufacturer chooses.

Here are some die casting steps for a high-pressure die cast:

Step 1: Preparation

In this stage, you need to spray a lubricant within the die cavity.

The lubricant assists in controlling the temperature level of the mold.

Also, it will enable the easy removal of the magnesium cast before closing the mold.

Step 2: Filling

Here, you will fill the molten magnesium metal in a mold at high pressures.

The pressure range can vary between 10 MPa to 175 MPa.

After filling the molten magnesium metal, you will maintain the pressure level until the magnesium cast solidifies.

Step 3: Injection

Here, you will open the die and then eject the shots using ejector pins.

The shots vary from one casting to another since they may have several cavities within the die.

This feature allows you to make several castings for every shot.

Step 4: Shake Out

This process entails the separation of the scraps.

These include rubbers, flash, gates, and spures.

Shake out process happens through the extrusion of the casting via specialized dressing dies.

Alternative sand falling techniques entail grinding and sawing.

Step 5: Defect Inspection

Once you complete the shake-out stage, you can check for any defects on the magnesium cast.

Some of the common types of defects include cold heading and stagnation.

magnesium Die Casting Machine

How Can You Protect Die Cast Magnesium Parts From Galvanic Corrosion?

Galvanic erosion in die cast magnesium components happens when different metals contact the magnesium die cast.

Also, this will happen in the presence of electrolytes like saltwater.

Besides, there is no worry about the internal parts.

However, the body, power-train, or chassis magnesium casting are prone to galvanic corrosion hence require some form of protection.

The protection process entails isolating the different metals.

This can happen through the coating of one of the parts or applying isolating elements such as washers to avoid the galvanization effect.

Which Mould Should You Use In Magnesium Die Casting?

The most common material that you will use to make the mold of magnesium die casting is steel.

Also, you can use it in various forms assisting you in producing various characteristics of the mold.

The most popular forms you will use are H13 and H11.

H13 Steel Mold

Besides, the reasons for using steel in making the mold include the following:

Machinability

This feature allows you to machine and make high-quality final products.

Heat Treatment

This allows you to have suitable mold life.

Dimensional Stability

This entails machining and heat-treating to eliminate stresses such as thermal, machining, or transformational stresses.

Which Secondary Operations Do You Use After Magnesium Die Casting?

Depending on the operation of the magnesium die cast, it can be complete following ejection and trimming.

However, other magnesium die casting need extra processing following the main die casting process.

These include the following:

Trimming

This entails eliminating flash from the magnesium die casting after exiting the die.

Magnesium die casting contain flash, which includes the following attachments:

1. Runners
2. Metal extensions
3. Gates
4. Overflows

Machining

The machining of magnesium die casting entail the following:

1. Drilling
2. Milling
3. Tapping

Impregnation

This entails forcing other organic substances into the pores that are on the surface of the magnesium die casting.

Also, you can minimize the cost by conducting pressure tests on all magnesium die castings.

After that, you will impregnate the magnesium die casting that fails to meet this specification.

Surface Finish

There are several types of surface finish that you can apply to magnesium die casting.

The surface finish will assist with:

1. Enhancing the appearance
2. Increase resistance to corrosion from various elements
3. Enhance the hardness
4. Increase the wear resistance

How Do Hot Chamber And Cold Chamber Magnesium Die Casting Compare?

Here is how these two processes compare:

Hot Chamber Magnesium Die Casting

In this process, the pressure cylinder and plunger are dipped in molten magnesium metal within a crucible.

Besides, hot-chamber magnesium die casting has a short casting duration that lasts about 1 second.

Also, it is costly to maintain this version than to maintain the cold chamber version.

 Illustration Of Hot Chamber Magnesium Die Casting

The hot-chamber magnesium die casting entails the following:

1. The plunger moves upwards thus enabling the molten metal to fill the cylindrical void
2. After that, you will close the die
3. The plunger moves downwards forcing the molten metal via a gooseneck to the cavity die
4. Afterward, you will hold the plunger under pressure until the metal solidifies once you fill the die
5. Open the die and the magnesium cast will remain in the die that contains ejectors
6. The plunger moves upwards and the surplus molten metal moves through the gooseneck to the holding vessel
7. Ejectors will push the magnesium die cast out from the die

Cold Chamber Magnesium Die Casting

Here, the temperature of the chamber where you will introduce the molten metal is cold.

The chamber is maintained at room temperature before introducing the molten metal.

Here is the process of cold chamber magnesium die casting:

1. Start by filling the pressure chamber with molten magnesium metal
2. Force the plunger to move forward to increase the pressure that will make the molten metal flow via the spruce
3. The molten metal moves via the spruce to the cavity
4. Once the metal cools and solidifies, the plunger will retract to the original position
5. This allows you to get ready for filling fresh molten metal within the cavity
6. The die will open and the ejector pins will remove the magnesium die cast from the die
7. The magnesium die casting process can now be repeated

Components Of Cold Chamber Die casting

What Are Some Variations Of Magnesium Die Casting?

These variations are meant to overcome any errors, flaws, or other problems that you may encounter in a magnesium die casting.

The variants include:

Pore Free

Here, you will fill the die cavity with oxygen before pouring the molten magnesium metal.

The oxygen will combine with the metal chemically hence preventing the formation of gas pores within the casting.

Acurad

This variation will combine a stable fill and a directional solidification process to form rapid cycle times.

It entails the following:

1. Heat treatable casting
2. Thermal analysis
3. Indirect squeezing

Gravity

Here, you will pour and fill molten magnesium metal in a permanent die.

The parts are stiff, high quality, strong, and with good mechanical traits.

Investment

This is a labor-intensive method that shapes the mold from a wax template that you will dip in a ceramic liquid substance.

Besides, you will pour molten metal into the ceramic cavity once the ceramic hardens and the wax melts off.

Semi-solid

Here, you will swirl, pour, then send the slurry molten metal to a shot sleeve.

Then you will force it using pressure to go within a die cavity.

Vacuum-assisted High Pressure

Here, you will place the die in an airtight system.

Afterward, you will create pressure to draw the molten metal where you will eject it after solidification.

Low Pressure

Here, the chamber is below the magnesium die which will push upwards via an inlet port to the die chamber.

Also, you will maintain pressure until it will solidify.

What Types Of Dies Can You Use In Magnesium Die Casting?

A die caster will use different dies to cast numerous components containing various features and characteristics.

The types of dies you can use include the following:

Single Cavity

This type has one cavity and can therefore form one cast per unit time.

Also, you will use a single cavity die when the die-cast equipment can make single cavity dies.

Besides, it will address the following:

1. Locking force
2. Shot height
3. Dimension of the die

Single cavity dies are suitable in scenarios where the production capacity is low.

Also, this process is suitable for making parts that require center gating and complex parts requiring multidirectional side cores.

Multiple Cavity

These dies use more than one cavity to produce identical components.

Besides, they are suitable for the following:

1. When there is a need to produce more magnesium die casting per unit time
2. Economically feasible when considering the cost of purchasing the equipment and making the magnesium die cast
3. When the machine can accommodate dies with several cavities

Combination Die

These dies have several cavities and can make several parts as opposed to multiple cavity die.

Combination dies are suitable when you need to lower the magnesium die casting costs.

Unit Die

These are small independent dies that you can insert within a main holding die, which is fixed.

Besides, you can alter the unit dies to make various magnesium die casting parts.

A majority of unit dies are single cavity dies.

How Does Magnesium Die Casting Compare To Aluminum Die Casting?

Aluminum die casting alloys happen within a cold chamber while magnesium die casting alloys happen in hot chamber equipment.

The magnesium alloy components are lightweight than the aluminum die casting components.

Also, the cost of performing aluminum die casting is less than that of magnesium die casting.

The casting cycle duration of aluminum die casting is lower than that of magnesium die casting.

Magnesium die casting has lower stability than aluminum die casting.

Besides, the magnesium die casts are easy to machine.

Magnesium die casting can form thinner walls than aluminum die casting.

Aluminum die casting has a better corrosion resistance than magnesium die casting.

Both the magnesium and aluminum die casting employ a high-pressure casting process.

Also, both of these processes are non-ferrous and are sturdier than most of the other metals.

What is Magnesium Die Casting Tooling?

Magnesium die casting tooling is an equipment that will assist with shaping the magnesium die casting component to a specific shape.

It represents a block with a cavity that forms dimensionally accurate components and allows for quick production.

The tooling has two halves, the feeding, and ejector portions.

Besides, you can use either permanent tooling that you can use repeatedly or temporary tooling that you will discard after use.

How Does Moving Die And Fixed Die Compare In Magnesium Die Casting?

Magnesium die casting uses two hardened dies that assist in forming suitable magnesium die castings.

Here is how these two compare:

Fixed Die

This die portion does not move and enables molten magnesium metal to move within it.

It will float towards the moving die once the molten metal is shaped.

Also, you will secure the fixed die to a stationary part of the mould.

Moving Die

Here, the ejection portion of the mould attaches to the die.

The ejector pins assist in ejecting the magnesium cast component and the runner.

Also, it will uniformly drive the pins to eject the molded portion effectively while maintaining its properties.

Which Defects Are Common During Magnesium Die Casting?

These include the following:

Flash

This happens when you use an extremely high injection pressure and the force of the clamps is very low.

Unfilled Sections

This occurs when you have an insufficient shot capacity.

Also, it may happen due to a slow injection or when you use a low pouring temperature level.

Bubbles

This will occur when you use an extremely high injection temperature or the rate of cooling is non-uniform.

Hot Tearing

This will happen when the rate of cooling the molten metal is non-uniform.

Ejector Marks

This will happen if the cooling duration is short or when the force of ejection is very high.

What Are Some Design Rules In Magnesium Die Casting?

These include the following:

Wall Thickness

Lower the maximum thickness of the wall of the component to minimize the cycle time and part volume.

Also, you will minimize defects when you have a uniform wall thickness as it will ensure the cooling rate happens uniformly.

Corners

Use round corners to minimize the concentration of stress and fracture.

Also, the thickness of the inner radius should be equal to or more than the wall thickness.

Draft

Ensure you use draft angles to all the walls in a parallel direction to the parting direction.

This will enhance the removal process of the component from the dies.

Undercuts

Here, you will lower the number of external undercuts.

External undercuts need side-cores that will increase the die casting cost.

Also, you can relocate the parting line to form a simple external undercut.

What Factors Will Affect The Cost Of Magnesium Die Casting?

These include the following:

Tooling Cost

The tooling cost contains two parts, the cavity machining and die sets.

Besides, the price of the die set is determined by the dimension of the envelope component.

Material Cost

Here, the cost is influenced by the material weight needed and unit cost.

The weight is determined by the volume and the density of the material.

Production Cost

This is a calculation of the cycle duration and the hourly rate.

Besides, the hourly rate and the dimension of the die casting equipment are proportional.

How Does Multi-Slide Tooling And Conventional Tooling Compare In Magnesium Die Casting?

Here is how these two compare:

Multi-slide Tooling

This tooling has several benefits such as:

1. First-time net shape
2. Complex shape and tight tolerance at a high speed
3. Less part-to-part alteration than conventional tooling
4. It will eliminate secondary processes such as machining and assembly
5. The compact tooling is less prone to the parting-line variety

Conventional Tooling

This tooling is made with several or single cavities.

Besides, it is efficient and reduces secondary processes that minimize cost.

Other advantages include:

1. Steel dies that are braced to increase their longevity
2. The dies are efficient enough to manage high productions
3. Effective production with cooling and the water lines that are suitably planned
4. Net die casting shape avoids secondary processes

What Is High Pressure Magnesium Die Casting?

This is a rapid and accurate technique of forming parts that you can make from magnesium.

Besides, it will offer the quickest way from molten magnesium to the final cast.

Also, it injects the molten magnesium into a steel mould enabling it to solidify in high pressure before conducting ejection.

What Are Some Types Of Cold And Hot Chamber Magnesium Die Casting Processes?

These include:

Low Pressure

This is suitable for magnesium alloys with low melting points and will enhance accuracy and utilization.

Vacuum

This process improves strength and causes minimal porosity.

It uses a cylindrical vacuum that forces molten magnesium in a mould cavity.

Squeeze Casting

Here, you will cast the molten magnesium alloy with no turbulence or trapping the gas.

Also, it happens under high pressure to form dense, high quality, and heat treatable parts.

Semi-solid Casting

In this process, you will use semi-solid billets to produce dense and heat treatable magnesium die casting.

Also, the cast has low porosity.

What Is Draft Angle In Magnesium Die Casting?

This is the angle or slope that you will include on the walls of the magnesium die casting mould.

Also, it will make the opening of the magnesium die casting wider than the base.

What Factors Affect The Lifespan Die Cast Magnesium Parts?

These entail the following:

Stress Concentration

The stress endurance of the mold needs to withstand the pressure levels.

Machining

For the machine to ensure different stress concentrations, you need to perform suitable finishing.

If you fail to perform this, the mold will deteriorate quickly.

Heat Treatment

When heat treatment and stress surpass the yield limit, the mold will occur.

Besides, thermal stress can make the mold fail early or quenching of the components.

Grinding And EDM

If you fail to conduct the grinding time properly, grinding cracks occur due to high surface stress and tissue alteration.

Production Operation

Ensure you perform injection and ejection at suitable time frames so as not to affect the molds.

What Are The Benefits Of Heat Treatment In Magnesium Die Casting?

These include:

• Minimal surface oxidation that causes minimal deformation
• Highly durable molds offer case hardening causing minimal fracturing
• Increase the machinability of molds
• Minimal surface decarburization
• Low operation costs as mold become flexible
• Increase in resistance to heat, wear, and corrosion
• Flexibility as mold softens and outer surface hardens

What Heat Treatments Are Available For Magnesium Die Casting?

Some methods of heat treatment include:

• Quenching
• Annealing
• Tempering

Is There Recommended Tolerance During Magnesium Die Casting?

The tolerance concerns various applications like the function, form, and fitment of the magnesium die casting.

Besides, the expression is in units like hundredths or thousandths of millimeters.

The tolerance allows for higher precision when producing parts, and averages at +/- 0.010 inches for every single inch.

Which Surface Finishes Can You Apply On Magnesium Die Cast Components?

These include:

• Anodizing
• Chromate
• Powder coating
• E-coat
• Chrome plated
• Chem film
• Bright nickel
• Cobalt tin
• Black oxide
• Siler
• Teflon
• Gold plating
• Nickel-free coating
• Impregnation
• Polyurethane paint

Anodized Magnesium Die Cast

Additional Resources:

• Magnesium Alloys
• Die Casting Process
• Aluminum Die Casting
• Die Cast Aluminum Alloys
• Surface Treatments
• Zinc Die Casting

For your questions or inquiry on magnesium die casting, contact us now.