Aluminum Alloys
 
 A201     356     535
 A204    A356    712
 A206    A357    771
 319      D357    850
      355      A413    RR350
 C355     354      520
    380      A380     B380
   LM6      LM25    LM31
 

Aluminum is one of the few metals that can be cast by all of the processes used in casting metals. These processes, in decreasing order of amount of aluminum casting, are: die casting, permanent mold casting, sand casting and green sand and dry sand.

There are many factors that affect selection of a casting process for producing a specific aluminum alloy part. The most important factors for all casting processes are:

• Quality factors

• Cost factors

Quality factors are important in the selection of a casting process. When applied to castings, the term quality refers to both degree of soundness (freedom from porosity, cracking, and surface imperfections) and levels of mechanical properties (strength and ductility).

 For a considerable number of castings, however, dimensions or design features automatically determine the best casting method. In terms of feasibility, many aluminum alloy castings can be produced by many available methods. Because metal molds weigh from 10 to 100 times as much as the castings they are used in producing, most very large cast products are made as sand castings rather than as die or permanent mold castings. Small castings usually are made with metal molds to ensure dimensional accuracy.

However, it should be kept in mind that in die casting, although cooling rates are very high, air tends to be trapped in the casting, which gives rise to appreciable amounts of porosity at the center. Extensive research has been conducted to find ways of reducing such porosity; however, it is difficult if not impossible to eliminate completely, and die castings often are lower in strength than low-pressure or gravity-fed permanent mold castings, which are more sound in spite of slower cooling.

All heat treatments available upon request.
 
 Magnesium Alloys
 
 AZ81    A K1A
 AZ91C   WE43A
 AZ91D   WE54A
 AZ91E    ZE41A
 AZ92A   EZ33A  AZ63
 

There is a dramatic growth by automotive companies to reduce component mass, and to take advantage of specific physical and/or inherent mechanical properties of magnesium alloys. Magnesium alloys are being specified at an increasing rate for structural applications, particularly in the area of automotive engineering. It has come to the attention of original equipment manufacturers and suppliers to this industry that superior product performance can be obtained by the use of cast magnesium alloy. A total engineering approach including appropriate material grade selection, component design, casting manufacture, machining and assembly has been adopted by this group. Some manufacturers and first tier suppliers have adopted a magnesium strategy as part of their business operations, where substitution of metal components with magnesium castings is a key part of their future platform planning, involving purchasing and advanced engineering groups. Magnesium casting substitution offers the maximum benefit in the replacement of multi component fabricated assemblies by a fully integrated die casting. This has been achieved for a number of magnesium seat designs around the world.

AZ91D grade magnesium alloy exhibits excellent die cast ability, with good strength and moderate ductility. It has been considered for decades as the grade of first choice if not discounted by specific property requirements. Typical applications include manual transmission housings, pedal brackets, intake manifolds, steering column and lock housings and mirror brackets to name a few.

 All heat treatments available upon request.