Alloy Data
2 Aluminum Alloys
Selecting Aluminum Alloys
Aluminum (Al) die casting alloys have a specific gravity of approximately 2.7 g/cc, placing them among
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 tables for chemical composition, typical proper-
ties, and die casting, machining and finishing characteristics for 11 aluminum die casting alloys.
This data can be used in combination with design engineering tolerancing guidelines for aluminum
die casting and can be compared with the guidelines for other alloys in this section and in the design
engineering section.
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 difficult 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 compo-
nents.
Alloy B390 (ANSI/AA B390.0) was developed for automotive engine blocks. Its resistance to wear is
excellent but, its ductility is low. It is used for die cast valve bodies and sleeve-less piston housings.
Alloy 218 (ANSI/AA 518.0) provides the best combination of strength, ductility, corrosion resis-
tance and finishing qualities, but it is more difficult to die cast.
* Different sets of properties can be achieved with alternate processes (such as high vacuum, squeeze,
and semi-solid casting) and alternate alloys (such as A356, Aural 2 or 356, and Silafont 36). Informa-
tion on these processes and alloys can be found in the Product Specification Standards for Die castings
produced by Semi-Solid and Squeeze Cast Processes (NADCA Publication #403) and the High
Integrity Die Castings book (NADCA Publication #404).
Machining Characteristics
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 associ-
ated 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.
Surface Treatment Systems
Surface treatment systems are applied to aluminum die castings to provide a decorative finish, to form
a protective barrier against environmental exposure, and to improve resistance to wear.
Decorative finishes can be applied to aluminum die castings through painting, powder coat finish-
ing, polishing, epoxy finishing, and electro-chemical processing. Aluminum can be plated by applying
an initial immersion zinc coating, followed by conventional copper-nickel-chromium plating procedure
3-4 NADCA Product Specification Standards for Die Castings / 2015
