03. Die Casting Alloys

7/18/2019 03. Die Casting Alloys

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1

DIE CASTING ALLOYS

By Siddharth Baraskar

PGTE 04116



2

INTRODUCTION

DIFFERENT ALLOY SYSTES Aluminium alloys

Zinc alloys

Magnesium alloys

Copper alloys

Tin alloysLead Alloys

Ferrous alloys



3

IPORTANCE

(GOVERNING FACTORS FOR SELECTION)

Cost

Die life

Physical properties – flowability, corroio!r"ita!c", w"ar r"ita!c", "tc#

Mechanical properties – t"!il" tr"!$t%,

%ar&!", "lo!$atio!, i'act tr"!$t%, "tc#Thermo-phy. properties – t%"r'al "a!io!,

'"lti!$ ra!$", &"!ity, # %"at caacity, "tc#



*

COST

Aluminium and Magnesium are aundantut their e!traction is a long process

ma"ing them costly.

Copper and Zinc are less aundant and are

less costly to e!tract. #ut their yield from

ore is less than $% and in future &e mayface prolems in otaining them.



+

DIE LIFE

Cold Chamer Process T%"r" i l" ti'" "or" of t%" '"lt to t%" l!$"r

wall or t%" l!$"r# T%i i articlarly " '"tal

c% a Al'i!' a!& Co"r t%at t"!& to "aily alloy

wit% Iro! at t%" %i$%"r t"'"ratr"#

'ot Chamer Process

T%" '"tal "& for t%i roc" ar" of low '"lti!$

oi!t a!& %i$% fli&ity c% a Ti!, -a$!"i', .i!c,a!& L"a& t%at t"!& !ot to alloy "aily wit% t""l at t%"ir

'"lt t"'"ratr"#



/

Alloys Li(uidous )olidousFree*ing+ange

!i"# a$$%y &4'1( AI) *+, *+- .

A$/i"/si$i#%" a$$%ys

+(Si 60. .,, -+

10(Si .20 .,, 1*

11(Si .+. .,, +

1-(Si .+- .,, .

A$/i"/si$i#%"#%33r a$$%y&10'.( Si5 *'.( C/)

.+0 .-0 60

Alloy "& i! &i" cati!$ %a0" fr""i!$ ra!$", fro' a

f"w &"$r"" for t%" i!c alloy wit% * al'i!' to o0"r

a %!&r"& &"$r"" for 'a$!"i' alloy#



A$/i"/a"si/a$$%ys

.( 6*. .20 4.

,5.( 6-. .60 6.

10'0( 610 .-. +.

a"si/ a$$%y &2( AI) .26 46+ 1-+Brass &60( C/5 *2'.( !"50'.( AI)

210 200 10

A$/i"/ 7r%"8&+2( C/5 10( AI5 1( F)

10.* 1040 1*

Lad a$$%y &.( S7) *10 -,0 40



4

5i" i!"rt 'a6i!$ t%" oti&" %a" of a! al'i!'

alloy &i" cati!$ will b" ""ct"& to lat i! $oo&

co!&itio! o0"r 1+7 777 %ot# If t%" &i" i!"rt lat 'or" t%a! 377 777 %ot, it i a

i$! of "c"ll"!t &"i$! of art, tool a!& "l"ctio! of

roc" ara'"t"r#

-a$!"i' %a a i'ilar '"lti!$ oi!t to t%at ofal'i!' bt it "ro&" &i" t""l to a l""r "t"!t, o

&i" li0" ar" ""ct"& to b" at l"at 2+ "r c"!t lo!$"r

for "8i0al"!t &"i$! a!& ro&ctio! co!&itio!#

C alloy r"r" &i" i!"rt ar" ally 'a&" of

"cial 'at"rial w%ic% $i0" $r"at"r r"ita!c" to %i$%

t"'"ratr", bt "0"! o &i" li0" of o!ly 27 777 %ot

ar" to b" ""ct"&#



9

ALUINIU ALLOYS

Al'i!i' &i" cati!$ ar" li$%tw"i$%t a!& ca!wit%ta!& t%" %i$%"t o"rati!$ t"'"ratr" of all &i"

cat alloy#

I&"al for &"'a!&i!$ "!0iro!'"!t, t%"y off"r %i$%tr"!$t% a!& ri$i&ity alo!$ wit% $oo& corroio!

r"ita!c" a!& %"at &iiatio!#



17

:r" Al'i!' i rar"ly cat &" to %i$% %ri!6a$",

a!& c"tibility to %ot crac6i!$#

Al'i!' i cat at a t"'"ratr" of /+7 ;C (1277 ;F)#

It i alloy"& wit% Silico! 9 a!& Co"r abot 3#+#

Silico! i!cr"a" t%" '"lt fli&ity, r"&c"

'ac%i!ability# A %i$% ilico! alloy $i0" %i$% w"arr"ita!c"#

Co"r i!cr"a" %ar&!" a!& r"&c" t%" &ctility#

<y $r"atly r"&ci!$ t%" a'o!t of Co"r t%"c%"'ical r"ita!c" i i'ro0"&, for'lat"& for " i!

'ari!" "!0iro!'"!t#



11

A$$%y A*+0 *+* B*20

ISO A$Si+C/*F A$Si1,C/4

USA AST *+0 *+* *20

E/r%3 EN 46.00

Fra"# NF AS2U*AY4 Gra"y DIN GA$Si+C/*

Ita$y UNI .0,.

N%r9ay NS

P%rt/a$ NP S3ai" UNE

S9d" SIS

U: BS L-4 L*0

;a3a" ;IS ADC10 ADC1-



12

atria$ Si$i#%" C%33r T"si$Str"thPa &ksi)

Pr%3rtis

AA 347(=NS A73477)

4#+ 3#+ 32*(*)

Fair "ay to fill

AA 34*(=NS A734*7)

11 * 331(*4)

Eay to fill

AA 34/(=NS A734/7)

9#+ 7#/ 31(*/)

Goo& corroio!r"ita!c"

AA 397(=NS A73977)

1 *#+ 243(*1)

Goo& w"arr"ita!c"

C%%" a$/i"/ a$$%y systs <%r di #asti" =

AERICAN STANDARD SPECIFICATIONS



13

A$/i"i/ a$$%y #hara#tristi#s=

> >ihst %3rati" t3rat/rs

> O/tsta"di" #%rr%si%" rsista"#

> Liht 9iht

> ?ry %%d str"th a"d hard"ss

> G%%d sti<<"ss a"d str"tht%9iht rati%

> E@#$$"t thra$ #%"d/#tiity

> >ih $#tri#a$ #%"d/#tiity

> G%%d <i"ishi" #hara#tristi#s

> F/$$ r#y#$a7i$ity



1*

A$/i"i/ A$$%y A*+0 &L-4)

Alloy A347 i o!" of t%" 'ot co''o!ly "cifi"&al'i!i' alloy, i!c" it off"r t%" b"t co'bi!atio! of

cati!$ a!& '"c%a!ical a!& t%"r'al ro"rti"# Fli&ity,

r"r" ti$%t!" a!& r"ita!c" to %ot crac6i!$ ar" all

0"ry $oo&# Roo' t"'"ratr" t"!il" tr"!$t% i lar$"ly

r"tai!"& to t"'"ratr" i! t%" or&"r of 1+7°C, a!&

aroi'at"ly %al0"& at 2+7°C#

a#hi"a7i$ity

Alt%o$% t%" 'ac%i!ability of A347 alloy i co!i&"r"&

to b" 8it" $oo&, t%" alloy &o" %a0" a t"!&"!cy to b"

o'"w%at abrai0" &" to t%" fairly %i$% ilico! co!t"!t#



1+

C%rr%si%" rsista"#

R"ita!c" to attac6 !&"r !or'al at'o%"ric

co!&itio! i fairly $oo&# I! 'ari!" at'o%"r", or

!&"r ot%"r "0"r" co!&itio!, cati!$ %ol& b"

rot"ct"& by ai!ti!$#

A33$i#ati%"s

5i" cati!$ i! L-2* ar" itabl" for 'ot "!$i!""ri!$

alicatio!# It i "& for a wi&" 0ari"ty of ro&ct

i!cl&i!$ c%ai for "l"ctro!ic "8i'"!t, "!$i!"brac6"t, $"arbo ca", %o"%ol& fr!itr", ow"r a!&

%a!& tool#



1/

A$/i"i/ A$$%y *+*

T%i alloy i a! alt"r!ati0" to A347 a!& i oft"! "cifi"&w%"! 0"ry i!tricat" co'o!"!t r"8ir" i'ro0"& &i"

filli!$ c%aract"ritic a!& i'ro0"& r"ita!c" to %ot

crac6i!$# 343 Alloy alo %a b"tt"r corroio! r"ita!c"#



1

A$/i"i/ A$$%y B*20 &L*0)

<397 i a al'i!i'?ilico! alloy, w%ic% wa ori$i!ally&"0"lo"& a a w"ar?r"ita!t alloy for ato'oti0"

"!$i!" bloc6# R"ita!c" to w"ar i "c"ll"!t# @ow"0"r,

t%" alloy %a 0"ry low &ctility wit% "lo!$atio! aro!&

1#

Its /s i" %thr a33$i#ati%"s has @3a"dd t% i"#$/d

a$ 7%dis5 #%3rss%r h%/si"s a"d %thr

#%3%""ts s/7#t t% a7rasi%" a"d 9ar5 s/#h as

7ari"s'

Srfac" tr"at'"!t yt"' actally allow "!$i!" ito!to r! &ir"ctly o! t%" alloy, ooi!$ t%" !""& for iro!

li!"r i! t%" cyli!&"r bloc6# -ac%i!i!$ of t%i alloy

r"8ir" "cial co!i&"ratio!#



14

Chara#tristi# A$/i"i/ Di #asti" A$$%y

A*+0&L-4)

*+* B*20&L*0)

R"ita!c" to @ot Crac6i!$ A 2 1 *

:r"r" Ti$%t!" 2 2 *

5i"?filli!$ Caacity < 2 1 1

A!ti?Sol&"ri!$ to t%" 5i" F 1 2 2

Corroio! R"ita!c" G * 3 3

-ac%i!i!$ Ea" a!& ality C 3 2 +

:oli%i!$ Ea" a!& ality E 3 3 +

El"ctrolati!$ Ea" a!& ality 5 1 1 3

A!o&ii!$ (A"ara!c") @ 3 3 +

C%"'ical Oi&" :rot"cti0" coati!$ I * * +

Str"!$t% at El"0at"& t"'"ratr" B 3 2 3

R$ati s#a$= 1 %st dsira7$5 . $ast dsira7$'



19

A Resistance to hot cracking # T%" ability of a! alloy to wit%ta!& t%" tr"" $"!"rat"&

&ri!$ co!tractio!, w%il" cooli!$ t%ro$% t%" %ot?%ort or brittl" t"'"ratr" c%a!$"#

< Die-filling capacity. Ability of 'olt"! '"tal to flow r"a&ily i! t%" &i" a!& fill t%i! "ctio!#

C Machining ease and quality # A co'oit" rati!$ ba"& o! "a" of ctti!$, c%i

c%aract"ritic, 8ality of fi!i% a!& tool lif"#

5 Electroplating ease and quality # T%" ability of a &i"cati!$ to ta6" a!& %ol& a!

"l"ctrolat" ali"& by ta!&ar& '"t%o&#

E Polishing ease and quality. Co'oit" rati!$ ba"& o! "a" a!& ""& of oli%i!$ a!&

8ality of fi!i%, ba"& o! tyical oli%i!$ roc"&r"#

F Anti-soldering to the die. Ability of 'olt"! alloy to flow wit%ot tic6i!$ to t%" &i"

rfac"# Rati!$ $i0"! for a!ti?ol&"ri!$ ar" ba"& o! !o'i!al iro! co'oitio! of 1#

G Corrosion resistance. <a"& o! r"ita!c" of alloy i! a ta!&ar& alt ray t"t#

@ Anodising (appearance). Rat"& o! li$%t!" of color, bri$%t!", a!& !ifor'ity of cl"ar

a!o&i"& coati!$ ali"& i! l%ric aci& "l"ctrolyt"# G"!"rally al'i!i' &i"cati!$ ar"

!itabl" for li$%t color a!o&ii!$ w%"r" a l"ai!$ co'"tic a"ara!c" i !"c"ary#I Cheical o!ide protecti"e coating. Rat"& o! co'bi!"& r"ita!c" of coati!$ a!& ba"

alloy to corroio!#

B #trength at ele"ated teperature. Rati!$ ba"& o! t"!il" a!& yi"l& tr"!$t% at

t"'"ratr" to 2/7C (+77F), aft"r rolo!$"& %"ati!$ at t"ti!$ t"'"ratr"#



27

C%3aris%" Ta7$ %< Casti" Chara#tristi#s %< a%r

A$/i"i/ Casti" A$$%ysBRITIS> STANDARD SPECIFICATIONS

L6 L-4 L*1

T"si$ Str"th &N-

) 160120 1+0 -1.

E$%"ati%" &() . 1'. 4

Bri"$$ >ard"ss .0.. +. ,0

D"sity &#*) -'6. -',2 -'+1

Fr8i" ra" &C a33r%@') .,..6. .+0.-0 61..,0

E E@#$$"t G G%%d F Fair P P%%r U U"s/ita7$

http://www.mrt-castings.co.uk/design_lm6.html








21

L6 L-4 L*1

Thra$ C%" &#a$#- #C -.dC) 0'*4 0'-* 0'*.

E$#tri#a$ C%" &( #%33r std' -0C) *, -4 *.

a#hi"a7i$ity P G G

C%rr%si%" Rsista"# E F E

E$#tr% P$ati" S/ita7i$ity F &1) F F

Casti" Chara#tristi#s G E F


1 Ths a$$%ys5 #%"tai"i" Si$i#%"5 r/ir a %di<i#ati%" trat"t <%r %%d adhsi%"

- Ca" 7 3$atd5 7/t "%t r#%"dd









22

A$/i"i/ A$$%y L6

Alloy L-/ i a!ot%"r co''o!ly "cifi"& al'i!i'alloy# It off"r $oo& corroio! r"ita!c" ro"rti" wit%

"c"ll"!t fli&ity#

T"!il" tr"!$t% a!& %ar&!" &"cr"a" fairly r"$larly

wit% i!cr"ai!$ t"'"ratr" a!& b"co'" r"lati0"ly oor

at 2+7°C#

a#hi"a7i$ity

Alloy of t%i a!& i'ilar co'oitio! ar" rat%"r &ifficlt

to 'ac%i!", &" to t%"ir t"!&"!cy to &ra$ a!& to t%"rai& tool w"ar ca"& by t%"ir %i$% Silico! co!t"!t#



23

C%rr%si%" Rsista"#

L-/ "%ibit "c"ll"!t r"ita!c" to corroio! !&"r bot%

or&i!ary at'o%"ric a!& 'ari!" co!&itio!# For t%"

"0"r"t co!&itio!, t%i ro"rty ca! b" frt%"r "!%a!c"&

by a!o&ic tr"at'"!t#

A33$i#ati%" a"d G"ra$ "%ts

L-/ i itabl" for 'ot 'ari!" cati!$, wat"r?cool"&'a!ifol& a!& Dac6"t, 'otor car a!& roa& tra!ort

fitti!$, t%i! "ctio! a!& i!tricat" cati!$ c% a 'otor

%oi!$, '"t"r ca" a!& witc% bo", for 0"ry lar$"

cati!$, "#$# cat &oor a!& a!"l w%"r" "a" of cati!$i ""!tial, for c%"'ical a!& &y" i!&try cati!$, "#$#

' art, a!& for ai!t i!&try a!& foo& a!& &o'"tic

cati!$# It i ""cially itabl" for cati!$ t%at ar" to b"

w"l&"&#



2*

Othr a%r a$$%yi" $"ts

T%" al'i!i' alloy wit% low"r a"si/ co!t"!tca! b" r"r" &i" cat# @"at tr"at'"!t to i'ro0"

'"c%a!ical ro"rti" i oibl" wit% t%" AI?-$4 a!&

AI?-$17 alloy#

T%" 'ot wi&"ly "& alloy yt"' i! w%ic%

'a$!"i' i r""!t at a r"lati0"ly low bt 0"ry

i'orta!t l"0"l i t%" AI?Si?-$7#3 ty"# T%" alloy

%ow a $oo& co'bi!atio! of catability, '"c%a!ical

ro"rti" a!& corroio! r"ita!c" a!& i wi&"ly "&

i! $"!"ral "!$i!""ri!$ a!& for al'i!' w%""l#



2+

%"r" %i$% tr"!$t% a!& %i$% &ctility ar" r"8ir"& it i

co''o! to fi!& ir%" co!t"!t of 7#2 or l" b"i!$

"cifi"&# I! r"r" &i" cati!$, iro! %"l to r"0"!t

t%" ol&"ri!$ w%ic% ca" cati!$ to tic6 i! t%" &i"#

a"a"s to 7#+ i alloy"&#

T%" "'brittli!$ "ff"ct of iro! ca! b" co!t"r"& by'a!$a!"" a&&itio! w%ic% c%a!$" t%" trctr" of t%"

i!t"r'"tallic %a"#

Ni#k$ i li'it"& to a 'ai'' of 7#+ or "0"! low"r

li'it# It i'ro0" t%" %i$% t"'"ratr" tr"!$t% of t%"

alloy#



2/

Rati"Gr%/3

A$$%ys

Cla A AI?-$+, AI?-$17,AI?C17?Si2

Cla< AI?Si+?C3, AI?Si/?C*?.!, AI?Si4?C3, AI?Si?-$7#3,

AI?Si9?C3?-$, AI?Si?C2

Cla C99#+AI, AI?Si 1 7?C2?F", AI?Si 12?-$,

AI?Si 11?-$?C

Cla 5 AI?Si12, AI?Si12?F"# AI?Si+

Alloy i! Cla A ar" "ai"t to 'ac%i!", t%"'ac%i!ability &"cr"ai!$ t%ro$% to Cla 5#

a#hi"a7i$ity Rati"s %< th C%%"

A$/i"/ Casti" A$$%ys



2

APPLICATIONS



24

BRA:EDRU>UB

CRAN:CASE

CRAN:CASE

CO?ER

>UBCO?ER

TRANSISSION

CASE



29

CYLINDER BLOC:

CYLINDER >EAD

CYLINDER >EAD CO?ER



37



31

.i!c ca! b" 'a&" to clo" tol"ra!c" a!& wit% t%i!!"rwall t%a! Al'i!', &" to it %i$% '"lt fli&ity#

.i!c i alloy"& wit% Al'i!' (*), w%ic% a&&

tr"!$t% a!& %ar&!"#

T%" cati!$ i &o!" at a fairly low t"'"ratr" of

*2+ ;C (477 ;F) o t%" art &o" !ot %a0" to cool

'c% b"for" it ca! b" "D"ct"& fro' t%" &i"# T%i, i!

co'bi!atio! wit% t%" fact t%at .i!c ca! b" r! i!$ a%ot c%a'b"r roc" allow for a fat fill, fat cooli!$

(a!& "D"ctio!) a!& a %ort cycl" ti'"#

!INC ALLOYS



32

!i"# A$$%y Chara#tristi#s=

> >ih str"th a"d hard"ss

> E@#$$"t $#tri#a$ #%"d/#tiity

> >ih thra$ #%"d/#tiity

> L%9st #%st ra9 atria$> >ih di"si%"a$ a##/ra#y a"d sta7i$ity

> E@#$$"t thi" 9a$$ #a3a7i$ity

> A7i$ity t% #%$d <%r5 9hi#h ass %i"i"

> >ih /a$ity <i"ishi" #hara#tristi#s

> O/tsta"di" #%rr%si%" rsista"#

> F/$$ r#y#$a7i$ity



33

Chara#tristi# !aakDi#asti" A$$%y

!A Di#asti" A$$%y

- * . , !A+ !A1- !A-,

R"ita!c" to @otCrac6i!$

1 1 2 1 2 3 *

:r"r" Ti$%t!" 3 1 2 1 3 3 *Cati!$ Ea" 1 1 1 1 2 3 3

:art Co'l"ity 1 1 1 1 2 3 3

5i'"!io!al

Accracy

1 1 1 1 2 2 3

5i'"!io!alStability

* 2 2 1 2 3 *

C%%" !i"# A$$%ys




3*

Chara#tristi# !aak Di#asti"A$$%y

!A Di#asti" A$$%y

- * . , !A+ !A1- !A-,

Corroio!R"ita!c"

2 3 3 2 2 2 1

-ac%i!i!$ Ea" a!&ality

1 1 1 1 2 3 *

:oli%i!$ Ea" a!&ality

2 1 1 1 2 3 *

El"ctrolati!$ Ea"a!& ality

1 1 1 1 1 2 2

A!o&ii!$ (:rot"ctio!) 1 1 1 1 1 2 2

C%"'ical Coati!$(:rot"ctio!)

1 1 1 1 2 3 3




3+

!i"# A$$%y - &A$ *'.4'*(5 C/ -'.*'0()

.i!c Alloy 2 i o'"ti'" r"f"rr"& to a ir6it"# T%ialloy off"r t%" %i$%"t tr"!$t% a!& %ar&!" of t%"

fa'ily# @ow"0"r, &" to t%" %i$% co"r co!t"!t (3),

c%a!$" to t%" 'at"rial ro"rti" occr wit% lo!$?t"r'

a$"i!$# Alt%o$% t%i alloy "%ibit "c"ll"!t cati!$

c%aract"ritic, it %a ""! li'it"& " by &i"cat"r# It

cr"" "rfor'a!c" i rat"& %i$%"r t%a! t%" ot%"r i!c

alloy a!& it 'ai!tai! %i$%"r tr"!$t% a!& %ar&!"

l"0"l aft"r lo!$?t"r' a$"i!$#

5"i$!"r of trctral co'o!"!t %ol& b" awar" of

t%" #r3 li'itatio! of i!c alloy, w%ic% &o !ot %a0" a

i!$l" 0al" for "latic 'o&l or yi"l& tr"!$t%#



3/

!i"# A$$%y * &A$ *'.4'*(5 C/ 0'-.(a@')

No# 3 Alloy i t%" 'ot wi&"ly "& i!c alloy i! Nort% A'"rica#

It "c"ll"!t bala!c" of &"irabl" %yical a!&

'"c%a!ical ro"rti", "rb catability a!& lo!$?

t"r' &i'"!io!al tability ar" t%" r"ao! w%y 'ot&i"cati!$ ar" 'a&" fro' t%i alloy#

No# 3 Alloy alo off"r "c"ll"!t fi!i%i!$

c%aract"ritic for lati!$, ai!ti!$ a!& c%ro'at"

tr"at'"!t# I! t"r' of &i"cati!$, it i t%" ta!&ar&

by w%ic% ot%"r i!c alloy ar" rat"&#T%i alloy "%ibit "c"ll"!t &a'i!$ caacity a!&

0ibratio! r"&ctio! i! co'ario! wit% al'i!i' &i"

cati!$ alloy#



3

!i"# A$$%y . &A$ *'.4'*(5 C/ 0',.1'-.()

No# + Alloy i t%" 'ot wi&"ly "& i!c alloy i! Ero",wit% it %i$%"r co"r co!t"!t r"lti!$ i! %i$%"r tr"!$t%

a!& i!cr"a"& %ar&!" at t%" ""!" of o'" lo of

&ctility (i!cr"a"& "lo!$atio!) co'ar"& to Alloy 3# T%i

ca! aff"ct for'ability &ri!$ "co!&ary o"ratio! c%

a b"!&i!$, ri0"ti!$, wa$i!$ or cri'i!$ o"ratio!#

@ow"0"r, w%"! a '"ar" of t"!il" "rfor'a!c" i

!""&"&, alloy + cati!$ ar" r"co''"!&"&#

T%i alloy i r"a&ily lat"&, fi!i%"& a!& 'ac%i!"&,

co'arabl" to alloy 3#%"r" t"'"ratr" abo0" !or'al ar" i!0ol0"& a!& t%"

co'o!"!t %a to !&"r$o trctral loa&, Alloy + i

li6"ly to b" a b"tt"r c%oic"#



34

!i"# A$$%y , &A$ *'.4'*(5 C/ 0'-.(a@')

Alloy i a 'o&ificatio! of Alloy 3# It i a %i$%?rityalloy co!tai!i!$ low"r 'a$!"i' co!t"!t a!& %a a

ti$%t"r i'riti" "cificatio!# T%i r"lt i! i'ro0"&

cati!$ fli&ity, &ctility a!& rfac" fi!i%# -ot alloy

i "& for "cial %ar&war" alicatio!, or w%"!cati!$ r"8ir" "tra for'ability# T%" %i$%"r fli&ity

alo allow t%i!!"r wall a!& i!tricat" &"tail to b" cat#

I! or&"r to a0oi& "c"i0" fla%i!$ alo!$ t%" tool

arti!$ li!", $oo& &i" fit a!& clo" co!trol of cati!$

roc" ara'"t"r i !"c"ary#T%" %i$% &ctility "%ibit"& by t%i alloy alo %a a!

i'act o! roc"i!$, bt 'ai!ly i! "co!&ary

o"ratio! for fla% r"'o0al a!& tri''i!$#



39

!i"# A$$%y !A+ &A$ +'0+'+(5 C/ 0'+1'*(a@')

T%" .A alloy co!tai! i$!ifica!tly 'or" al'i!i't%a! t%" .a'a6 $ro of alloy#

It i articlarly itabl" for &"corati0" alicatio!#

Alt%o$% t%i alloy &o" !ot "%ibit 8it" a $oo&

cati!$ c%aract"ritic a t%" ot%"r i!c alloy, itoff"r i$!ifica!tly i'ro0"& tr"!$t%, %ar&!" a!&

cr"" ro"rti"#

I! t"r' of '"c%a!ical "rfor'a!c", t%i alloy %a

t%" %i$%"t cr"" tr"!$t% of a!y i!c alloy a!& t%"

%i$%"t tr"!$t% of a!y %ot?c%a'b"r &i"cat i!calloy# .A?4 co!tai! aroi'at"ly 4#* al'i!i'

a!& i t%" o!ly .A alloy t%at ca! b" %ot?c%a'b"r

&i"cat#



*7

!i"# A$$%y !A-, &A$ -.-+(5 C/ -'0-'.(a@')

.A?2 co!tai! aroi'at"ly 2 al'i!i'# 5" tot%" %i$% al'i!i' co!t"!t of t%i alloy, it 't b"

col&?c%a'b"r &i" cat#

T%i alloy %a t%" %i$%"t tr"!$t%, a!& t%" low"t

&"!ity of t%" .A alloy# .A?2 ro0i&" t%" %i$%"t&"i$! tr" caability at "l"0at"& t"'"ratr" of all

t%" co''"rcially a0ailabl" i!c?ba"& alloy#

T%i alloy alo %a "c"ll"!t b"ari!$ a!& w"ar

r"ita!c" ro"rti"#



*1

!i"# A$$%y AC/!i"#. &A$ -'+*'*(5 C/ .'06'0()

T%i i a! alloy r""arc%"& a!& &"0"lo"& by G"!"ral

-otor, w%ic% "%ibit $r"atly i'ro0"& tr"!$t%,

%ar&!" a!& cr"" "rfor'a!c" &" to t%" %i$%

co"r a!& low al'i!i' co!t"!t# T%i alloy alo%a "c"ll"!t b"ari!$ ro"rti"#



*2

ZA3 ZA12 ZA27Tensile Strength (N/mm2) 283 276-310 400-440

Elongation (%) 15 3-4 3-6

Brinell Hardness 83 105-125 110-120

Density (g/cm3) 6.7 6.03 5.0

Freezing range (C approx.)387-382 430-380 490-380

Thermal Con. (cal/cm2 /cm/C

@ 25C) 0.27 0.21 (112.5)

Electrical Con. (%copper std.

@ 20C)

26 25 28


C%3aris%" Ta7$ %< Casti" Chara#tristi#s %< a%r

!" A$$%ys



*3

ZA3 ZA12 ZA27

Machinability E E E

Corrosion Resistance E E E

Electro Plating Suitability E G F

Non Spark Yes Yes No

Casting Characteristics - Sand G E E

Casting Characteristics - Gravity G E G

Casting Characteristics- High

Pressure

E F F




**

APPLICATIONS



*+



*/



*



*4

AGNESIU ALLOYS

-a$!"i' i t%" i&"al 'at"rial for alicatio!w%"r" w"i$%t a0i!$ i a riority, %a0i!$ t%" low"t

&"!ity of all trctral '"tal#

Al'ot a li$%t i! w"i$%t a latic, 'a$!"i' %a

t%" a&0a!ta$" of $r"at"r tr"!$t% a!& ri$i&ity alo!$wit% i!%"r"!t E-I %i"l&i!$, &rability, %"at?

&iiatio! a!& fll r"cyclability#



*9

a"si/ A$$%y Chara#tristi#s=

>Th $ihtst %< a$$ str/#t/ra$ ta$s

>E@#$$"t sti<<"ss a"d str"tht%9iht rati%

>O/tsta"di" EI shi$di" 3r%3rtis

>>ih #%"d/#tiity5 $#tri#a$ a"d thra$

>Hithsta"ds hih %3rati" t3rat/rs

>C%st<<#ti aai"st 3$asti#s

>>ih di"si%"a$ a##/ra#y a"d sta7i$ity

>E@#3ti%"a$ thi" 9a$$ #a3a7i$ity>G%%d "ir%""ta$ #%rr%si%" rsista"#

>G%%d <i"ishi" #hara#tristi#s

>F/$$ r#y#$a7i$ity



+7

Chara#tristi# a"si/ Di #asti" A$$%y

A!21D A60A

R"ita!c" to Col& 5"f"ct 2 3

:r"r" Ti$%t!" 2 1

R"ita!c" to @ot Crac6i!$ 2 2

-ac%i!i!$ Ea" a!& ality 1 1

El"ctrolati!$ Ea" a!& ality 2 2

Srfac" Tr"at'"!t 2 1

5i" Filli!$ Caacity 1 2

A!ti?Sol&"ri!$ to t%" 5i" 1 1

Corroio! R"ita!c" 1 1

:oli%i!$ Ea" a!& ality 2 2

C%"'ical Oi&" :rot"cti0" Coati!$ 2 1

Str"!$t% at El"0at"& T"'"ratr" * 3




+1

a"si/ A$$%y A!21D&A33r%@' 10( A$ !"5C/5Si5"5F5Ni $ss tha" 0'*(

a#h)

Alloy A.915 i t%" 'ot wi&"ly "cifi"& 'a$!"i' &i"

cati!$ alloy# T%i %i$%?rity alloy %a a! "c"ll"!t

co'bi!atio! of '"c%a!ical ro"rti", corroio!r"ita!c", a!& catability# Corroio! r"ita!c" i

ac%i"0"& t%ro$% t%" "!forc"'"!t of 0"ry trict li'it o!

t%r"" '"tallic i'riti" iro!, co"r a!& !ic6"l# T%""

ar" li'it"& to 0"ry low l"0"l 'a6i!$ it !"c"ary to "

ri'ary 'a$!"i' i! t%" ro&ctio! of t%i alloy# Awit% all 'a$!"i' alloy, "cial r"catio! 't b"

ta6"! w%"! 'ac%i!i!$#



+2

a"si/ A$$%y A60A&A33r%@' 6( A$ !"5C/5Si5" $ss tha" 0'* ( a#h)

-a$!"i' alloy A-/7A i "& i! alicatio!

r"8iri!$ $oo& "lo!$atio!, to$%!" a!& i'act

r"ita!c" co'bi!"& wit% r"ao!ably $oo& tr"!$t% a!&

"c"ll"!t corroio! r"ita!c"#T%" i!cr"a"& &ctility "%ibit"& by t%i alloy i a

co!"8"!c" of t%" r"&c"& al'i!i' co!t"!t#

@ow"0"r t%i alo r"lt i! a r"&ctio! of tr"!$t% a!&

oor"r catability# A wit% all 'a$!"i' alloy, "cial

r"catio! 't b" ta6"! w%"! 'ac%i!i!$#



+3

E<<#ts %< T3rat/r5 Ti a"d E"ir%""t %"

#ha"i#a$ Pr%3rtis %< a"si/ a$$%ys

It i i'orta!t t%at w%"! &"i$!"r ar" "l"cti!$ t%"

aroriat" 'a$!"i' alloy for a articlar

"!0iro!'"!t t%at all of t%" factor ar" co!i&"r"&# I!

a&&itio! to "!0iro!'"!tal "ff"ct, t%"r" i a c%a!$" i!t%" '"tallr$ical trctr" of t%" alloy o0"r a "rio& of

ti'", a!&Hor at "l"0at"& t"'"ratr", t%at aff"ct t%"

'"c%a!ical ro"rti"# So, #r3 i a! i'orta!t

co!i&"ratio! i! 'a$!"i' art for "l"0at"&

t"'"ratr" ", tr"" a!& ti'" of o"ratio!%ol& b" 6!ow! for bot% "a6 a!& !or'al co!&itio!#



+*

APPLICATIONS



++

C=TTING -HC COVER

-OTORCCLE REAR COVER -OTORCCLE :ARTS

S-ALL :ARTS



+/STEERING @EEL

S@ELLS FOR IT :RO5=CTS



+

COPPER ALLOYS

T%" r"f"rr"& alloy for &i"cati!$ ar" baically t%o"wit% $oo& fli&ity a!& low '"lti!$ oi!t to r"&c" &i"

w"ar a!& $oo& %ot t"ar r"ita!c" to o0"rco'" t%"

tr"" arii!$ &ri!$ oli&ificatio!#

T%" alloy wit% abot *7 "r c"!t i!c ar" itabl" for&i"cati!$# T%" a&&itio! of frt%"r alloyi!$ "l"'"!t

'ay alt"r t%" roortio! of "ac% %a"#



+4

C%%" additis=

L"a& i a&&"& to i'ro0" 'ac%i!ability#

Al'i!' ro0i&" r"ita!c" to oi&" for'atio! by

ro&ci!$ a rfac" fil' of al'i!' oi&" o! t%"

bra i! bot% t%" 'olt"! a!& oli& tat"#

I! low co!c"!tratio! ilico! r"&c" lo of i!c a!&

i'ro0" fli&ity#Iro! i a co''o! i'rity# It i!cr"a" tr"!$t% bt i

&"tri'"!tal to corroio! r"ita!c" a!& ca! ro&c"

%ar& ot if it "$r"$at"#

-a!$a!"" alo i!cr"a" tr"!$t% a!& it r""!c"i!cr"a" t%" a'o!t of iro! t%at ca! b" ta6"! i!to

oltio!#

Ti! ca! i'ro0" '"c%a!ical ro"rti"# Ti! low"r t%"

'"lti!$ oi!t a!& i!cr"a" fli&ity#

C%33r a$$%ys <%r di #asti"



+9

S3#i<i#ati%" C/ !" S" P7 Ni F " Si

US a$$%ys

C +.+00 .,i" Ba$ 1'. 1'. 0'.0 0'.. 0'-. 0'-.

C +6.00 ..60 *64- 1'. 0'*0 0'+ -'. 1'.

C +6+00 .4., *1*2 1'. 0'-0 0'+ -'.-'.4'0

C +,+00 +0+* 1-16 0'-. 0'1. 0'-0 0'-. 0'1. *'+4'-

C +1200 6*6, *0*6 0'-. 0'-. 0'.0 0'.0 0'1.0',.1'-

C22,.0 ..61 1,-* 0'*. -'. .'0 1'. 1,-*

C%3%siti%"s sh%9" as ( a@i/ /"$ss sh%9" as a ra" %r i"i/

33 y



/7

S3#i<i#ati%" C/ !" S" P7 Ni F " Si

U: a$$%ys

DCB1 .26* Ba$ 0'-.

DCB* .+6* Ba$ 1'0 0'.-'. 1'0 0'+ 0'. 0'0.

PCB1 .,60 Ba$ 0'. 0'.-'. 0'*

>TB1 ..i" Ba$ 1'0 0'.0 1'0 0',-'0 *'0J 0'10

Pr%3ritarya$$%ys

A ta$1 64'. Ba$ 1'0 -'. 0'1. 0'* 0'.

O ta$- 6*'. Ba$ 0'. -'0 0'. 0'. 0',

Br%"9it* .2'. Ba$ 0'. 1'. 0'. 12'. 0'.



/1

Th rat at 9hi#h th di dtri%rats

d3"ds ai"$y /3%" th <%$$%9i" <a#t%rs=

1#Cati!$ &"i$! i robably 'ot i'orta!t#

2#-ot of t%" crai!$ occr i! t%" ar"a of t%" $at" a!&

it i fo!& to b" a&0a!ta$"o if t%" &ir"ctio! of f""& i

alo!$ t%" cati!$ wall rat%"r t%a! acro t%" wall#

3#T%" rfac" t"'"ratr" of t%" &i" aff"ct t%"

roc" i! two way# @i$%"r &i" t"'# r"&c" t"'#

$ra&i"!t a!& low"r &i" t"'# r"&c" t%"r'al fati$"

*#:ori!$ t"'"ratr" %ol& b" co!troll"&#

P%i"ts t% r7r=



/2

1# Co'o!"!t &"i$! %ol& a0oi&, a far a oibl",

c%a!$" i! wall t%ic6!"#

2# Allowa!c" for b"8"!t 'ac%i!i!$ %ol& !ot "c""&7#+ ''#

3# Gati!$ %ol& b" i!to t%" t%ic6"r "ctio! a!& alo!$ t%"

wall of t%" co'o!"!t, a0oi&i!$ trbl"!c"#

*# -ai'' i!D"ctio! r"r" %ol& b" "&# :r"r" to 2777 6$H c'2 ar" co''o!ly ali"&#

+# T%" ca0ity %ol& b" w"ll 0"!t"&# V"!t to 7#2 ''

&"" a!& 17 '' wi&" ar" ro0i&"& alo!$ t%" arti!$

rfac"#

/# Sl$ l"!$t% %ol& b" at l"at 2+ '' to "!r" r"r"

i 'ai!tai!"& at t%" $at" !til it oli&ifi"#

# T%" low"t i!D"ctio! ""& t%at a0oi& 'ir!, "tc#,

%ol& b" "&#

P%i"ts t% r7r=



/3

Co"r alloy ar" "& i! l'bi!$, "l"ctrical a!& 'ari!"

alicatio! w%"r" corroio! a!& w"ar r"ita!c" i i'orta!t#

APPLICATIONS

-



/*

Brass PDCs <%r

a/t%%7i$s=

15*5, a"d + ar

ar7%@ 3artsK

4 a"d 6 ar

7attry 3artsK

- #%""#ti"

$rK

. hati" a$'

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*4

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-



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Brass PDCs

<%r 3$/7i"

a"d sa"itary

<itti"s



//

Parts <%r s3ri"k$r a"d 3/3

Hatr #ir#/$at%r r%t%rs



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i"i/ 9a$$ thi#k"sss a"d i"i/ dra<t

a"$s <%r di #asti" ar =

atria$i"' Thi#k"ss

&i")i"' Dra<t A"$ &)

Al'i!'

alloy

7#9 ''

(7#73+ i!)7#+

.i!c alloy7#/ ''

(7#72+ i!)7#2+

Co"r alloy

(<ra)

1#2+ ''

(7#7+7 i!) 7#

Ty3i#a$ #ha"i#a$ Pr%3rtis



/4

Ty3i#a$ #ha"i#a$ Pr%3rtis

A$/i"/ Brass a"si/ !i"#

T"si$ str"th5&3a)

32* *77 23+ 247?*27

Yi$d str"th5 &Pa) 224 277 1/7 227?37

Shar str"th5&Pa)

277 2/7 134 21+?32+

Fati/ str"th5&Pa)

1*7 17 47 *4?1*+

E$%"ati%"5&( i" .0 )

1 ? * 27 3 ? 4 2 ? 13

>ard"ss &Bri"$$) /+ ? 127 133 /3 47?127



/9


D"sity &#'#') 2# 4#* 1#4 /#

$ti" Ra" &%C) +17?/+7 447?977 *7?/1+ 347?*/7

Thra$ #%"d/#tiity5&H%C)

9/?13* 179 /2?2 177?12+

C%<<' %< Thra$

@3a"si%"5&M%C) 27#7 21#7 2#7 2#*

E$#tri#a$ #%"d/#tiity5&(IACS)

2 2/ 12 2

%d/$/s %< $asti#ity5&GPa)

1 177 *+ 4+#+

I3a#t str"th &;) 3?/ 1/ 3?/ *4?/+

Fi i hi D ti



7

Fi"ishi"= D#%rati


Chr% 3$ati" Fair Ec"ll"!t Fair Ec"ll"!t

B$a#k #hr% 3$ati" Fair Ec"ll"!t ?? Ec"ll"!t

C%$%rd 3$ati" Fair ?? ?? Ec"ll"!t

#ha"i#a$3%$ishi" 7/<<i"

Ec"ll"!t Ec"ll"!t Ec"ll"!t Ec"ll"!t

La#/rs5 "a$s53%@is a#ry$i#s


A"%di8i" Fair ?? ?? ??



1

Pr%t#ti


A"%di8i"#%rr%si%" a7rasi%" 3r%t#ti%"

Ec"ll"!t ?? Goo& Ec"ll"!t

Chr%at #%"rsi%"#%rr%si%"

Ec"ll"!t ?? Ec"ll"!t Ec"ll"!t

>ay 3ai"t5 9ri"k$5att <i"ishsa7rasi%"5#%rr%si%" 3r%t#ti%" t%

hid i3r<#ti%"s


Th %st satis<a#t%ry th%ds %< <i"ishi" a#h s3#i<i# ta$#



2

Pr%#ssi" a"d Pr%d/#ti%"

a#hi" Ty3s= A$/i"/ Brass a"si/ !i"#

>%t #ha7r &P$/"r) No No " "

C%$d #ha7r " " " "

Pr%d/#ti%" ra"5sh%tshr

*7?277 *7?277 +?*77 277?++7

Ara t%%$ $i<5 "%' %<sh%ts @ 1000

12+ 27 277 +77

Chara#tristi#s %< Di Casti" A$$%ys



3

Chara#tristi#s %< Di Casti" A$$%ys


5i'"!io!altability

Goo& Ec"ll"!t Ec"ll"!t Goo&

Corroio!r"ita!c"

Goo& Ec"ll"!t Fair Fair

Cati!$ "a" Goo& Fair Goo& Ec"ll"!t

:art co'l"ity Goo& Fair Goo& Ec"ll"!t

5i'"!io!alaccracy

Goo& Fair Ec"ll"!t Ec"ll"!t

5i" cot -"&i' @i$% -"&i' Low

-ac%i!i!$ cot Low -"&i' Low Low

Fi!i%i!$ cot -"&i' Low @i$% Low



*

Th Di Casti" B%%k 7y Arth/r Strt

999'dy"a#ast'#%

999'rt#asti"s'#%'/k

999'I"dia"I"d/stry'#%

999'Chi"aa"si/'#% &Y%"ka" Tsh" Hh$ C%')

999'a8a$$'#% &Eastr" A$$%ys C%')

999'/s'ss'#% &Prir Di Casti" C%')

999':yt%ta$s'#%

SOURCES=



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Documents

03. Die Casting Alloys