Die Casting Alloy Guide
Aluminum vs. Magnesium Die Casting Alloys
Compare two alloy directions through component weight, geometry, mechanical requirements, environment, surface protection and secondary machining.
Five project questions
Alloy Selection Shapes the Manufacturing Route
Alloy selected before geometry is reviewed
Draft, wall design, function and alloy direction need to be reviewed as one route.
Weight target is not balanced with structural needs
Component weight should be evaluated with stiffness, interfaces and environment.
Surface protection is considered late
Environment and protective finish can influence alloy and process preparation.
Secondary machining is not defined early
Precision interfaces and functional features need to be visible in drawing review.
Documentation is not agreed before sourcing
Project records should be confirmed with the selected production route.
AL / MG
Two Alloy Directions, Reviewed for Different Priorities
Aluminum Die Casting Alloys
A380 · A360 · ADC12
Balanced directions for structural components, equipment housings and thermal-management features.
- Review geometry, walls and interfaces with the selected alloy direction.
- Confirm environment, protection and secondary machining needs before release.
Magnesium Die Casting Alloys
AZ91D · AM60B · AM50A
Lightweight directions for integrated housings and selected portable structures.
- Review structure, environment and surface protection as one decision.
- Confirm secondary machining with the selected protection route.
Aluminum vs. Magnesium: Review Matrix
| Review dimension | Aluminum direction | Magnesium direction |
|---|---|---|
| Component weight | Balance weight with broad component use. | Review lower weight as a primary driver. |
| Structural needs | Review housings, thermal and functional interfaces. | Review integrated structures and stiffness needs. |
| Geometry | Confirm wall design, draft and manufacturing geometry. | Confirm thin-wall and integrated-structure requirements. |
| Operating environment | Confirm environment and finish requirements. | Confirm environment and protection requirements early. |
| Surface protection | Review intended cosmetic and protective finish. | Agree the protection route early. |
| Secondary machining | Review precision interfaces and finished features. | Review machined features with alloy and protection route. |
| Production quantity | Confirm with tooling, process and selected resource. | Confirm with tooling, process and selected resource. |
| Documentation | Agree records before material sourcing. | Agree records before material sourcing. |
Protection & finish
Surface Protection Is Part of the Alloy Decision
Review environment, cosmetic expectation and secondary machining sequence with the alloy direction. The right protection route depends on the component and project requirements.
Alloy Confirmation Before Production
- 01Drawing review
- 02Geometry and function review
- 03Alloy direction discussion
- 04Protection and machining review
- 05Availability and documentation agreement
- 06Manufacturing route confirmation
Material Selection FAQ
How are aluminum and magnesium alloy directions reviewed?
They are reviewed against component weight, geometry, environment, protection and machining needs.
Can die cast parts receive secondary machining?
Secondary CNC machining may be coordinated when precision features are required.
When should documentation be defined?
Documentation should be discussed before material sourcing and production release.