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   * Sand Casting
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MAGNESIUM DIE CASTING

Magnesium Die Castingadmin2020-09-21T22:58:17-04:00


MAGNESIUM DIE CASTING





OUR EXPERTISE OF MAGNESIUM CASTING (MAGNESIUM DIE CASTING)

We are very experienced in magnesium casting including magnesium die casting.
With strong capability of casting a wide variety of magnesium steel alloys such
as AZ91D, AM60B and AM50, we provide custom magnesium casting parts and
components for industries and applications including automotive, food & dairy,
machinery, medical, plumbing, watering, mining, petrochemical, electrical,
energy, aerospace, submarine and others. We can assure you high quality
magnesium castings.

For your magnesium casting and magnesium die casting needs, we can help you out
with our best services.




WHAT IS MAGNESIUM?

Magnesium is the lightest structural material, about 1.8 grams per cubic
centimetre. magnesium is the 8th most abundant element in the earth’s crust. It
occurs naturally in Dolomite, Magnesite, Carnallite and Chloride (sea water).
Magnesium is produced from sea water, brines and magnesium-bearing minerals
which offer unlimited reserves.

Magnesium is 75% lighter than steel, 33% lighter than aluminum, offers component
and feature integration and provides a high dimensional stability that improves
fit and finish.




BENEFITS OF MAGNESIUM

 * Lightest of all structural materials
 * 75% lighter than steel
 * 33% lighter than aluminum
 * High impact resistance
 * High strength to weight ratio
 * Can be cast to net shape
 * Excellent dimensional stability/repeatability
 * Abundant material supply
 * 100% recyclable





COMPARISON BETWEEN MAGNESIUM AND STEEL

Comparing to steel, magnesium is 75% lighter, with advantages such as component
consolidation/integration, significantly lower tooling costs, high heat
conductivity, complicated thin-walled near net shape and superior dimensional
stability/repeatability.


COMPARISON BETWEEN MAGNESIUM AND PLASTIC

Comparing to steel, magnesium is stronger, with advantages such as superior
stiffness, greater energy absorbing capabilities, higher temperature
applications and large thin-walled near net shape casting.


COMPARISON BETWEEN MAGNESIUM AND ALUMINUM

Comparing to aluminum, magnesium is 33% lighter, with advantages such as
superior machining, large thin-walled near net shape casting, greater mechanical
properties and greater general corrosion resistance.




MAGNESIUM ALLOYS WE DIE CAST

We help our customer to select alloy based on the environment the part will
function in the performance requirements of the component.

AZ91D: Most commonly used alloy for high pressure die casting. Offers good
strength to weight ratio, very good corrosion resistance and excellent
castability. This alloy is typically used for power-train and mechanical
components where toughness is more important than deformation capability.

AM60B: Commonly used for automotive die castings for safety components such as
instrument panel structures and seat frames. This alloy offers excellent
ductility, energy absorbing properties, strength and castability.

AM50: With a lower aluminum content than AM60 this alloy offers a further
increase in ductility but at a slightly reduced strength and a slight reduction
in castability. It is typically used where the performance requirements demand
elongation properties beyond that of AM60.

Notes: For applications such as power-train components where the operating
temperature is above 120 degrees C (example; automatic transmission housing)
there is a large selection of magnesium alloys available. These alloys are
designed to operate in the higher temperatures without “creep” so that bolt
tension and sealing surface flatness is maintained. Meridian recommends
discussing this with our engineering group to review the options available.




ADVANTAGES OF MAGNESIUM DIE CASTING

 * Lightest of all structural materials
 * Excellent Stiffness
 * Outstanding EMI and RFI shielding properties, perfect for connectors and
   electrical housings
 * Withstands high operating temperatures
 * Exceptional thin wall capability
 * Good environmental corrosion resistance
 * Excellent dimensional stability/repeatability
 * Good finishing characteristics
 * 100% recyclable





MAGNESIUM DIE CASTING MATERIAL INFORMATION

Mechanical Properties AZ91D AM60B AM50A Ultimate Tensile Strength (Mpa) 240 225
210 Yield Strength (Mpa) 160 130 125 Elongation (% ub 2 in (51mm) 3 8 10
Hardness (Brinell) 70 65 60 Elastic Modulus (Gpa) 45 45 45




Physical Properties AZ91D AM60B AM50A Density (g / cm³) 1.81 1.80 1.77 Melting
Range (F) 815 to 1,108 815 to 1,139 815 to 1,238 Melting Range (C) 435 to 598
435 to 615 435 to 620 Specific Heat (kJ/kg k) 1.02 1.02 1.02 Thermal
Conductivity (W / m – k ) 51 61 65 Electrical Conductivity (MS/m) 6.6 9.1 —
Corrosion Rate (mg/cm²/day) 0.05 0.09 0.1




SECONDARY OPERATIONS OF MAGNESIUM DIE CASTING

 * Painting using e-coat or powder coat processes
 * Machining




HOW DO WE PROTECT AGAINST GALVANIC CORROSION?

Galvanic corrosion occurs when dissimilar metal is in contact with the magnesium
casting and with an electrolyte presents such as salt water. There is no issue
with interior components. However for parts and components such as body, chassis
or power-train castings, there is a likelihood that galvanic corrosion
protection will be required. The approach is to isolate the dissimilar metals
either by coating one of the components or using an isolating material as a
washer to eliminate the galvanic effect.




MAGNESIUM CASTING TOOLING AND PROTOTYPE OPTIONS

We offers our customers several options for tooling and prototype parts
depending on the intended use of the parts. With requirements of various lead
times and tool life availability to meet all program schedules, tooling options
include sand casting tooling, die casting tooling, rapid tooling, and soft
prototype tooling.




MAGNESIUM DIE CASTING PARTS


magnesium die casting parts sku1
magnesium die casting parts sku2
magnesium die casting parts sku3

magnesium die casting parts sku4
magnesium die casting parts sku5
magnesium die casting parts sku6

oem vw magnesium engine case



 

Request for Quote


SOURCES

 * American Foundry Society. “Metal Casting”
 * Wikipedia. “Investment Casting“, “Sand Casting“
 * efunda. “Sand Casting“
 * FBSFittings, LLC. “Casting Fittings“
 * The Investment Casting Institute. “What is Investment Casting?“
 * FBSCasting, LLC. “Investment Casting Strainers“
 * The Library of Manufacturing. “Investment Casting“
 * BMG Titanium “Casting Titanium“
 * FDCasting, LLC. “Stainless Steel Casting“
 * Forging Industry Association “Forging Industry“


OUR INTERNAL RESOURCES FOR DIE CASTING, INVESTMENT CASTING, FORGING AND SAND
CASTING

 * Die Casting
 * Aluminum Die Casting
 * Zinc Die Casting
 * A356 Aluminum Casting with T6 Heat Treatment
 * Magnesium Die Casting
 * Investment Casting
 * Stainless Steel Casting
 * Duplex Stainless Steel Casting
 * Super Duplex Stainless Steel Casting
 * Titanium Casting
 * Carbon & Low Alloy Casting
 * Forging
 * Cold Forging
 * Hot Forging
 * ECO BRASS C69300 Brass Forging
 * Sand Casting (Aluminum Sand Casting, Ductile Iron Sand Casting, Gray Iron
   Sand Casting)
 * Specialty Fittings and Fasteners
 * Precision CNC Machining and Secondary Operations





CONTACT US

FORCEBEYOND

261 Quigley Blvd, Suite 18
New Castle, Delaware 19720
Phone: (302) 995 6588
Fax: (302) 355 1166
Email: contact at forcebeyond dot com






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