Magnesium die casting services
Not only is magnesium the lightest of all the structured materials but it has excellent stiffness and strength-to-weight ratios. Additionally, it has outstanding EMI and RFI shielding properties, perfect for connectors and electrical housings. It is also utilized for medical and laboratory equipment. ISO 9001:2015 and IATF 16949:2016 certified.
What is Magnesium Die Casting?
Magnesium die casting is a specialized manufacturing process utilized in the production of metal parts and components made from magnesium alloy. This process, often referred to as magnesium alloy die casting, involves injecting molten magnesium into a die or mold cavity under high pressure. The resulting product, also known as magnesium cast, is a complex shape or part that exhibits the unique properties of magnesium alloy.
The die casting manufacturing process for magnesium starts with the preparation of the magnesium alloy. The alloy is carefully melted in a furnace and subsequently injected into the die or mold cavity. Typically, the mold is constructed from durable materials such as steel and is meticulously designed to produce the desired shape of the final part.
Once the molten magnesium is introduced into the mold cavity, it undergoes rapid cooling and solidification under high pressure. This distinctive manufacturing method allows for the creation of intricate and complex shapes that would be challenging to achieve through alternative manufacturing processes.
Magnesium Die Cast Material
Magnesium Die Cast Material
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.
Magnesium Die Casting Surface Finishing
Choose from our various surface finish options to increase corrosion resistance and add vibrant colors to your Magnesium die cast parts.
Oil spray
Makes a product with rich color, uniform coating, environmental protection. The surface of die castings needs to be cleaned, deoxidized and chemically pretreated.
Tumbling
Tumbling smooths and polishes small parts by friction and abrasion in a barrel, offering a consistent but slightly textured finish.
Polishing
Polishing achieves a high gloss finish, reducing surface roughness and enhancing the aesthetic appeal of metals.
Sand Blasting
Sand blasting uses pressurized sand or other media to clean and texture the surface, creating a uniform, matte finish.
Anodizing
The magnesium alloy is used as an anode to form a protective oxide film on the surface of the magnesium alloy by the action of an applied voltage in a specific electrolyte.
Laser Carving
The physical degeneration of the melting and gasification of the processed material under laser irradiation achieves the processing purpose.
Phosphatization
By using specific phosphating solution, a layer of phosphating film with good anti-corrosion effect can be formed on the surface of magnesium alloy
Pad Printing
Printing picture or text on another object with the carrier improves the aesthetics of the product, and increases the added value and market competitiveness.
Benefits of Magnesium Die Castings
Magnesium is a top choice for die-casting due to its unique properties, such as strength and durability combined with a lightweight structure, which is similar to plastic. Its unique features such as castability, ease of machining, and recyclability make it an excellent material option for die-casting strong but lightweight components.
Magnesium alloys are 33% lighter than aluminum and 75% lighter than steel with excellent strength-to-weight ratio. With good thermal and electrical conductivity, magnesium is an excellent material choice for electronic components while also offering good shielding from electromagnetic or radio-frequency interference. Magnesium alloys have remarkable shock-absorbing properties that enable them to be used in applications where noise and vibration are of concerns.
Magnesium alloys, especially AS91D, have high fluidity, allowing for intricate features and thin walls to be casted. Although the cost of magnesium per pound is higher than aluminum or zinc, magnesium alloys provide more parts per pound and can offer significant cost savings in other ways. Magnesium has a lower heat capacity compared to aluminum, this means it will heat up and cool down faster, which decreases its production cycle time and increases productivity. Magnesium die casting machine tooling can last up to 4 times longer than its aluminum casting counterpart. Furthermore, magnesium die cast parts are easier to machine, requiring less time and decreasing machining costs, making magnesium a good material choice for projects that requires a lot of secondary machining. Although magnesium die-casted parts usually remain uncoated due to their excellent surface finish, a variety of surface treatment options are available, including powder coat, liquid paint, plating, and chromate.
Magnesium alloys are a sustainable material option that offer an environmentally-friendly alternative to plastics. The scrap material from magnesium parts is 100% recyclable and can be re-casted like raw material, making it an ideal choice for manufacturers who prioritize responsible and sustainable production methods.
Applications of Magnesium Die Castings
The medical, electronic, automotive, and aerospace industries widely utilize magnesium for their die-casted components due to its unique properties. If you have a project that could benefit from magnesium die-casting, we welcome you to contact us today. Our team of experts is ready to help you explore the exceptional benefits of this remarkable material.
With many magnesium die casting processes in our network, Amfas offers a wide range of options. Amfas’ use of the best people and equipment for the job at hand allows for tight tolerances in any production part that we fabricate. With over 15 years of casting experience, our team will ensure your parts are made with outstanding magnesium die-cast machine companies.
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