Die Casting Alloys & Materials Guide | Aluminum, Zinc, Magnesium | KastMfg

KastMfg processes aluminum, zinc, and magnesium alloys across 23 HPDC machines. Selecting the right alloy for your application is one of the most important decisions in a die casting program -the wrong choice creates problems in casting quality, mechanical performance, surface finishing, or cost that are difficult to correct after tooling is committed.

This page provides an overview of the alloys we process, with comparison data and selection guidance. Detailed pages for each alloy are linked below.

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Alloy Families Processed at KastMfg

Family	Alloys	Density	Casting Process	Die Life
Aluminum	A380, ADC12, A360, A413, A390	2.66-2.74 g/cm3	Cold chamber	80,000-150,000 shots
Zinc	Zamak 3, Zamak 5, ZA-8	6.60 g/cm3	Hot chamber	300,000-1,000,000+ shots
Magnesium	AZ91D, AM60B, AM50A	1.74-1.81 g/cm3	Hot chamber	100,000-200,000 shots

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Aluminum Die Casting Alloys

Aluminum is the most widely used die casting metal. Its low density, high strength-to-weight ratio, excellent thermal conductivity, and natural corrosion resistance make it the standard choice for automotive, industrial, and electronics applications.

A380 Aluminum ->

The world's most produced die casting alloy. Best overall balance of castability, strength, machinability, and cost. Default choice for general engineering.

• Tensile: 317 MPa | Yield: 159 MPa | Elongation: 3.5%
• Density: 2.71 g/cm3 | Thermal conductivity: 96 W/m·K

ADC12 Aluminum ->

Japanese standard (JIS H5302). Slightly higher silicon than A380 for improved castability and dimensional precision. Specified by Japanese automotive and electronics OEMs.

• Tensile: 310 MPa | Yield: 160 MPa | Elongation: 2.5%

A360 Aluminum ->

Higher silicon, lower copper. Superior corrosion resistance and thermal conductivity. Preferred for outdoor, marine, and thermal management applications.

• Tensile: 317 MPa | Corrosion resistance: best in aluminum die casting family

A413 Aluminum ->

Near-eutectic composition (12% Si). Lowest porosity, best pressure tightness. Standard specification for hydraulic manifolds and pneumatic valve bodies.

• Tensile: 290 MPa | Thermal conductivity: 121 W/m·K | Pressure tightness: best

A390 Aluminum

High silicon (17%), high copper. Maximum hardness and wear resistance. Used for cylinder liners and high-wear surfaces.

• Hardness: 120 HRB | Wear resistance: best in aluminum die casting

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Zinc Die Casting Alloys

Zinc die casting produces thinner walls, tighter tolerances, and smoother surface finish than aluminum -at the cost of higher density. Zinc is the preferred metal for decorative electroplating and high-precision small components.

Zamak 3 (Alloy 3) ->

The global baseline zinc alloy. Most widely produced. Best ductility (10% elongation), excellent castability, smooth surface ideal for decorative plating.

• Tensile: 283 MPa | Elongation: 10% | Min wall: 0.4 mm

Zamak 5 (Alloy 5) ->

Adds 1% copper for higher strength and hardness. Standard alloy in Europe. Preferred for load-bearing zinc applications.

• Tensile: 331 MPa | Yield: 228 MPa | Hardness: 91 HRB

ZA-8 (Zinc-Aluminum 8)

8% aluminum content gives highest strength of the zinc alloys processed in hot-chamber. Good bearing properties.

• Tensile: 374 MPa | Hardness: 100 HRB

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Magnesium Die Casting Alloys

Magnesium is the lightest structural die casting metal -35% lighter than aluminum. Inherent EMI shielding makes it standard for electronics enclosures and telecommunications equipment.

AZ91D Magnesium ->

Most widely used magnesium die casting alloy. Highest strength and best corrosion resistance in the AZ family. 34% lighter than aluminum.

• Tensile: 230 MPa | Density: 1.81 g/cm3 | EMI: 60-100 dB @ 1GHz

AM60B Magnesium ->

Lower aluminum content (6%) gives superior ductility (8% elongation) and impact resistance. Preferred for automotive safety structures subject to crash loading.

• Tensile: 220 MPa | Elongation: 8% | Impact: superior to AZ91D

AM50A Magnesium

Even lower aluminum (5%) for maximum elongation. Steering wheels, seat frames, and impact-critical automotive applications.

• Elongation: 10% | Best ductility in AZ/AM family

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Alloy Selection Matrix

Requirement	Recommended Alloy
General aluminum, best castability	A380
Japanese OEM specification	ADC12
Hydraulic pressure tightness	A413
Corrosion resistance (outdoor/marine)	A360
Decorative plating (chrome/nickel)	Zamak 3
Load-bearing zinc, higher strength	Zamak 5
Lightweight enclosures, EMI shielding	AZ91D
Automotive crash safety structures	AM60B
Thinnest walls (<0.8 mm)	Zamak 3
Maximum weight reduction	AZ91D / AM60B

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Alloy Property Quick Reference

Alloy	Density (g/cm3)	Tensile (MPa)	Min Wall (mm)	Die Life (shots)
A380	2.71	317	1.2	80,000-150,000
ADC12	2.74	310	1.2	80,000-150,000
A360	2.63	317	1.2	80,000-150,000
A413	2.66	290	1.2	80,000-150,000
Zamak 3	6.60	283	0.4	300,000-400,000
Zamak 5	6.60	331	0.4	300,000-400,000
ZA-8	6.30	374	0.6	200,000-300,000
AZ91D	1.81	230	0.8	100,000-200,000
AM60B	1.80	220	0.8	100,000-200,000

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Need Help Selecting an Alloy?

If your drawing specifies an alloy, KastMfg will supply to that specification with full material certification. If your application requires alloy selection, send us your drawing and application description -our engineers will recommend the optimal alloy with a technical rationale.

Email: yaoqingpu1983@gmail.com Phone / WhatsApp: +86 138 1403 4409 Address: No.6, Rungu Road, Nanjing, China