Aluminum die casting alloys have a specific gravity of approximately 2.7 g/cc, which was placed as the lightweight structural metals. The majority of die castings produced worldwide are made from aluminum alloys.
Six major elements constitute the die cast aluminum alloy system: silicon, copper, magnesium, iron, manganese, and zinc. Each element affects the alloy both independently and interactively.
This aluminum alloy subsection presents guideline for chemical composition, typical properties, and die casting, machining and finishing characteristics for the following aluminum die casting alloys.
Alloy A380 (ANSI/AA A380.0) is by far the most widely cast of the aluminum die casting alloys, offering the best combination of material properties and ease of production. It may be specified for most product applications. Some of the uses of this alloy include electronic and communications equipment, automotive components, engine brackets, transmission and gear cases, appliances, lawn mower housings, furniture components, hand and power tools.
Alloy 383 (ANSI/AA 383.0) and alloy 384 (ANSI/AA 384.0) are alternatives to A380 for intricate components requiring improved die filling characteristics. Alloy 383 offers improved resistance to hot cracking (strength at elevated temperatures).
Alloy A360 (ANSI/AA A360.0) offers higher corrosion resistance, superior strength at elevated temperatures, and somewhat better ductility, but is more difficult to cast.
While not in wide use and dicult to cast, alloy 43 (ANSI/AA C443.0) offers the highest ductility in the aluminum family. It is moderate in corrosion resistance and often can be used in marine grade applications.
Alloy A13 (ANSI/AA A413.0) offers excellent pressure tightness, making it a good choice for hydraulic cylinders and pressure vessels. Its casting characteristics make it useful for intricate components.
Alloy 390 (ANSI/AA B390.0) was developed for automotive engine blocks. Its resistance to wear is excellent; its ductility is low. It is used for die cast valve bodies and compressor housings in pistons.
Alloy 218 (ANSI/AA 518.0) provides the best combination of strength, ductility, corrosion resistance and finishing qualities, but it is more difficult to die cast.
Machining characteristics vary somewhat among the commercially available aluminum die casting alloys, but the entire group is superior to iron, steel and titanium. The rapid solidification rate associated with the die casting process makes die casting alloys somewhat superior to wrought and gravity cast alloys of similar chemical composition.
Alloy A380 has better than average machining characteristics. Alloy 218, with magnesium the major alloying element, exhibits among the best machinability. Alloy 390, with the highest silicon content and free silicon constituent, exhibits the lowest.