Magnesium Die Casting: The Lightweight Advantage

Material Properties

Magnesium alloys offer unique characteristics:
✓ Lightest structural metal (35% lighter than aluminum)
✓ Low melting point (650°C vs aluminum’s 660°C)
✓ Exceptional machinability (20% faster than aluminum)
✓ Premium material cost (1.5-2x aluminum price)
✓ High reactivity (requires special handling)

Process Advantages
• Hot-chamber casting for optimal fluidity
• Best strength-to-weight ratio of structural metals
• High-temp stability (up to 120°C continuous service)
• Superior EMI/RFI shielding (critical for electronics)
• Requires protective coatings for corrosion resistance

5-Step Production Process

1. Die Preparation

Automated spray cleaning & lubricating (300-400°C die temp)

2. Injection

600-650°C molten Mg injected at 3,000-6,000 psi

3. Solidification

Fast cooling (2-3x faster than aluminum)

4. Ejection

Precision ejection pins prevent part distortion

5. Finishing

Minimal machining required (0.1-0.3mm typical allowance)

Key Applications

• Aerospace components (seat frames, instrument panels)
• Automotive (steering wheels, transmission cases)
• Electronics (laptop housings, drone frames)

Technical Note: Our AZ91D and AM60B alloys deliver optimal corrosion resistance when combined with proprietary surface treatments.

Magnesium Die Casting Applications: Where Lightweight Matters Most

Magnesium die casting delivers critical advantages where weight reduction and electromagnetic protection are paramount. Key applications include:

1. Electronics & Telecom
   ✓ RF/EMI-shielded enclosures for 5G base stations
   ✓ Ultra-light drone and camera housings (30-50% weight savings vs aluminum)
2. Transportation Lightweighting
   • Automotive: Steering columns, seat frames (meeting CAFE standards)
   • Aerospace: Cabin components reducing fuel consumption by 2-3% per kg saved
   • E-bikes: High-strength structural parts with vibration damping
3. High-Performance Components

• Engine blocks with superior heat dissipation (up to 120°C continuous)
• Transmission cases using creep-resistant AE44 alloy
• Thermal management systems for EV batteries

Material Innovation
Our proprietary Mg-Al-Zn (AZ91) and Mg-RE (WE43) alloys offer:
✔ 20% higher ductility than standard grades
✔ Salt-spray corrosion resistance exceeding 500 hours
✔ Customizable thermal conductivity (50-130 W/mK)

Key Advantages of Magnesium Die Casting

1. Unmatched Lightweight Performance

• 35% lighter than aluminum (1.74 g/cm³ vs 2.7 g/cm³)
• 75% weight reduction vs steel components
• Ideal for weight-sensitive applications in aerospace and EVs

2. Superior Machinability

• 50% faster machining speeds vs aluminum
• 30% longer tool life reduces production costs
• Minimal burr formation for precision parts

3. Exceptional Castability

• Flows 20% farther than aluminum in thin-wall applications
• Achieves consistent 0.5mm wall thicknesses
• Excellent dimensional stability (±0.1mm tolerance)

4. Premium EMI/RFI Shielding

• 60-100dB attenuation across 10MHz-10GHz range
• Eliminates need for secondary shielding coatings
• Critical for 5G/6G telecom and military electronics

Technical Edge: Our magnesium die casting delivers:
✓ AM60B alloy for optimal strength-ductility balance
✓ Proprietary anti-corrosion treatments
✓ Integrated CNC machining capabilities