Die Casting Materials - Alloy Selection Guide
Complete guide to die casting materials: aluminum alloys A380, ADC12, A360, and A413, zinc Zamak 3, Zamak 5, and ZA-8, plus magnesium AZ91D and AM60B.
Materials Visual Plan
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Alloy Family Overview Image
Reserve one wide image showing representative aluminum, zinc, and magnesium castings together for quick visual comparison.
Material Detail Close-Up
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Application Example Image
Use a real component-in-application photo to connect each alloy family to practical OEM use cases.
Aluminum Alloys
Compare detailed alloy pages
A356 aluminum
A356 Aluminum Casting - Properties, T6 & Uses
A356 aluminum casting alloy: composition, mechanical properties, T6 heat treatment, and when to choose A356 vs A380 for gravity, low pressure, and die casting programs.
A383 aluminum
A383 Aluminum Die Casting | A380 Alternative
A383 aluminum die casting alloy: better die-filling and pressure-tightness than A380 for thin-wall and intricate parts. Composition, properties, and A383 vs A380 selection.
ADC12 die casting
ADC12 Aluminum Die Casting | JIS H5302 Alloy
ADC12 aluminum die casting alloy is widely used in Japanese automotive and electronics supply chains. Review JIS H5302 properties and applications.
aluminum for die casting
Aluminum for Die Casting: Alloy Selection Guide
Which aluminum for die casting? Compare A380, ADC12, A360, A413, and A390 for castability, strength, corrosion resistance, and cost - with a selection guide for OEM buyers.
A360 aluminum die casting
A360 Aluminum Die Casting - Corrosion Resistant
A360 aluminum die casting alloy with superior corrosion resistance and thermal conductivity versus A380 - ideal for outdoor, marine, and heat sink parts.
A390 aluminum die casting
A390 Aluminum Die Casting for Wear Resistance
A390 aluminum die casting: hypereutectic Al-Si alloy with 120 HRB hardness and maximum wear resistance for cylinder liners, pistons, and sliding surfaces.
A413 aluminum die casting
A413 Aluminum Die Casting | Pressure-Tight Alloy
A413 aluminum alloy is used for pressure-tight die casting in hydraulic and pneumatic parts. Review composition, properties, and application guidance.
A380 aluminum die casting
A380 Aluminum Die Casting | Properties and Uses
A380 is the most common aluminum die casting alloy for automotive, industrial, and electronics parts. Review composition, properties, and applications.
Zinc Alloys
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ZA-12
ZA-12 Zinc Alloy - Properties & Casting Guide
ZA-12 zinc-aluminum alloy (ZnAl11Cu1): 400 MPa tensile strength, the best bearing properties of the ZA family, and gravity or cold-chamber casting guidance.
ZA-27
ZA-27 Zinc Alloy - Highest-Strength Zinc Casting
ZA-27 zinc-aluminum alloy (ZnAl27Cu2): the strongest zinc casting alloy at 421 MPa tensile, for bearings, gears, and structural parts via gravity or cold-chamber casting.
Zamak 2
Zamak 2 Zinc Die Casting | Creep-Resistant Alloy
Zamak 2 (ZnAl4Cu3) zinc die casting alloy: 3% copper for the best creep resistance and long-term dimensional stability in the Zamak family. Properties and applications.
Zamak 3
Zamak 3 Zinc Die Casting | Properties and Uses
Zamak 3 is the standard zinc die casting alloy for hardware, plated parts, and consumer components. Review composition, properties, and applications.
Zamak 5
Zamak 5 Zinc Die Casting | Higher-Strength Alloy
Zamak 5 zinc die casting alloy offers higher strength than Zamak 3 for hardware and load-bearing parts. Review properties and applications.
zinc die casting alloys
Zinc Die Casting Alloys | Zamak 3, Zamak 5 & ZA-8
Compare zinc die casting alloys including Zamak 3, Zamak 5, and ZA-8 for strength, plating, dimensional accuracy, die life, and OEM applications.
ZA-8 zinc die casting
ZA-8 Zinc Die Casting - High-Strength Zinc Alloy
ZA-8 zinc die casting alloy with 374 MPa tensile strength - the highest of zinc alloys - plus superior bearing properties and temperature resistance.
Magnesium Alloys
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AM50 magnesium alloy
AM50 Magnesium Die Casting | Ductile Mg Alloy
AM50 magnesium die casting alloy: 10-15% elongation and superior impact strength vs AZ91D, for automotive safety parts, seats, and instrument panels. Properties and selection guide.
AM60B magnesium die casting
AM60B Magnesium Die Casting for Automotive Safety
AM60B magnesium die casting alloy for safety-critical automotive structures: 8% elongation and impact resistance versus AZ91D for crash-loaded parts.
AZ91D magnesium die casting
AZ91D Magnesium Die Casting | Properties and Uses
AZ91D is the standard magnesium die casting alloy for lightweight housings and structural parts. Review composition, properties, and applications.
Alloy Comparisons
Material comparison guides
ADC12 vs A380 die casting
ADC12 vs A380 Die Casting - Which Alloy to Specify
ADC12 vs A380 die casting alloys compared: composition, mechanical properties, castability, and when the JIS or ASTM grade is the correct specification.
Zamak 3 vs Zamak 5
Zamak 3 vs Zamak 5 - Choosing the Right Zinc Alloy
Zamak 3 vs Zamak 5 compared: Zamak 5 gains 17% tensile strength and 45% compressive yield from copper, while Zamak 3 keeps higher ductility at lower cost.
A360 vs A380 aluminum die casting
A360 vs A380 Aluminum Die Casting Alloy Compared
A360 vs A380 aluminum die casting compared: A360's low copper gives superior corrosion resistance and 18% higher thermal conductivity for a small premium.
A413 vs A380 die casting
A413 vs A380 Die Casting: How to Choose
A413 vs A380 aluminum die casting compared: composition, porosity, pressure tightness, strength, cost, and which alloy fits your part.
AZ91D vs AM60B magnesium die casting
AZ91D vs AM60B Magnesium Die Casting Alloy Guide
AZ91D vs AM60B magnesium die casting compared: static strength versus impact resistance and crash safety, and why 8% elongation matters for structures.
Selection Guide
Read the full alloy overview
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.
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 |
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. For a buyer-focused selection guide, see aluminum for die casting.
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
A383 Aluminum ->
Higher silicon (10.5%), lower copper than A380. Best die-filling of the 3xx HPDC family - for thin walls, dense fins, and leak-tight housings.
- Tensile: 310 MPa | Fluidity: best in HPDC aluminum
A356 Aluminum ->
Structural casting standard (7% Si, 0.3% Mg). T6-heat-treatable with 6-12% elongation. For gravity and LPDC structural parts, not standard HPDC.
- Tensile (T6): 290-330 MPa | Elongation: 6-12%
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
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
Zamak 2 (Alloy 2) ->
3% copper - highest strength and creep resistance of the Zamak family. For threaded inserts and sustained-load hardware. Note long-term aging shrinkage.
- Tensile: 359 MPa | Hardness: 100 HB
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
ZA-12 (Zinc-Aluminum 12) ->
11% aluminum. High strength with the best bearing/wear performance of the family. Cold-chamber or gravity only - not hot-chamber castable.
- Tensile: 400 MPa | Hardness: 95-115 HB | Bronze bushing replacement
ZA-27 (Zinc-Aluminum 27) ->
27% aluminum - the strongest zinc casting alloy. For heavy-duty bearings, gears, and structural parts. Gravity and cold-chamber casting.
- Tensile: 421 MPa | Density: 5.0 g/cm3 (lightest zinc alloy)
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
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 |
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 |
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: casting@kastdiecast.com Phone / WhatsApp: +86 138 1403 4409 Address: No.6, Rungu Road, Nanjing, China