Magnesium, Zinc, Aluminum Castings

Magnesium Castings: AZ91D, AM60B
Aluminum Castings: A356, A357, A380
(special alloy requests will be considered for aluminum castings)
Zinc: Castings Z3, Z12, Z27

Volume less than 3.0 ft.ł
determined by the maximum extent in each axis

.050” is common.
.025” or less is possible depending on feature geometry

Casting capabilities include thin walls, intricate geometry with multiple slides or cores, zero draft, and complex parting lines

The tolerances specified below apply only as general guidelines. Closer tolerances for castings can be and often are obtained. The geometry and design of the magnesium, zinc, or aluminum castings can be a significant factor in determining overall tolerances. Special procedures and secondary operations, such as machining, are regularly employed to hold tighter tolerances.

XY Direction:
±.005” 1st inch, ±.002” per inch for each inch thereafter

Z Direction, across parting lines:
+.015”/-.005”1st inch, ±.002” per inch for each inch thereafter

Location tolerance for mold inserts (cores - slides): ±.015

Angular alignment for mold inserts: ±.25°

Non-Castable features that must be machined:

Intersecting bores
Holes smaller than .50” diameter
with a depth/diameter ratio greater than 1.5
All holes less than .187” diameter

Tolerances for SLA patterns:
±.005” for less than 5”. ±.0015 per inch for each inch thereafter


Alloy	Temper	Tensile (Psi)	Yield (Psi)	% Elongation in 2"
Aluminum A356	T6	34,000	24,000	3.5
Aluminum A357	T6	41,000	31,000	3
Magnesium AZ91D	F	34,000	23,000	3
Magnesium AM60	F	32,000	19,000	6-8
Aluminum 380	F	46,000	23,000	3.5 (for die-cast reference)
304	Annealed	85,000	35,000	55
316	Annealed	85,000	35,000	55
1025	Annealed	80,000	68,000	19
4140	Annealed	95,000	60,500	26