Aluminum Die Casting Alloys: An Ultimate Selection Guide

Selecting Aluminum Alloys for Your Application

Aluminum is a versatile material with a wide range of properties, making it a popular choice for a variety of applications. When selecting an aluminum alloy for your application, it is important to consider the following factors:

  • Operating temperature: Aluminum alloys have a wide range of operating temperatures. Some alloys are designed for high-temperature applications, while others are better suited for lower-temperature applications.
  • Corrosion resistance: Aluminum is a naturally corrosion-resistant material, but some alloys are more resistant to corrosion than others. If your application will be exposed to harsh environments, you will need to select an alloy with good corrosion resistance.
  • Strength: Aluminum alloys come in a variety of strengths. Some alloys are designed for lightweight applications, while others are designed for high-strength applications.
  • Machinability: The machinability of an aluminum alloy refers to how easily it can be machined. Some alloys are easier to machine than others.
  • Cost: The cost of aluminum alloys varies depending on the alloy and the manufacturing process.

Once you have considered these factors, you can begin to narrow down your choices. There are many different aluminum alloys available, so it is important to do your research to find the right alloy for your application.

Commonly Used Aluminum Alloys for Die Casting

  1. Alloy 380: This is the most commonly used aluminum alloy for die casting and offers an excellent combination of material properties and cost-effectiveness. It possesses good fluidity, thermal conductivity, and can be easily cast and machined.
  2. Alloy 383 & 384: These alloys are often used as an alternative to 380 as they provide better die filling characteristics but at a slightly higher cost.
  3. Alloy 360: Offers greater corrosion resistance and superior strength at high temperatures compared to 380. However, it’s more expensive and requires specific casting conditions.
  4. Alloy 413: This is used for maximum pressure tightness and fluidity. It’s ideal for parts requiring intricate details.

Here are some of the most common aluminum alloys:

  • 6061: This alloy is a good all-around choice for most applications. It is strong, corrosion-resistant, and machinable.
  • 2024: This alloy is stronger than 6061 and is often used in high-strength applications. It is also more difficult to machine.
  • 7075: This alloy is the strongest aluminum alloy available. It is often used in aerospace applications.

If you are unsure which aluminum alloy is right for your application, consult with a metallurgist or a manufacturing engineer. They can help you select the right alloy for your specific needs.

Benefits of Using Aluminum Alloys

In addition to the properties mentioned above, aluminum alloys offer a number of other benefits, including:

  • Lightweight: Aluminum is one of the lightest metals available, making it a good choice for applications where weight is a concern.
  • Recyclable: Aluminum is a fully recyclable material, which can help to reduce waste and save resources.
  • Cost-effective: Aluminum alloys are often more cost-effective than other materials, such as steel or stainless steel.

If you are looking for a lightweight, corrosion-resistant, and recyclable material for your next project, consider using an aluminum alloy.

Please refer to the Google Doc for the standard composition and physical performance criteria for each grade.

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Aluminum die casting alloys are widely used in an array of industries due to their distinctive properties and benefits. Their unparalleled combination of lightweight and strength, excellent thermal conductivity, high dimensional stability, and corrosion resistance makes them ideal candidates for numerous applications in the automotive, electronics, and aerospace sectors. In this article, we’ll discuss the key factors that guide the selection of aluminum alloys for die casting and examine the materials best suited for the process.

Understanding Aluminum Die Casting

Die casting is a metal casting process that injects molten metal into a die or mold cavity under high pressure. The mold cavity is created using two hardened tool steel dies machined into shape and work similarly to injection molds.

Aluminum alloys are particularly suitable for this process because they offer excellent fluidity, which ensures the molten metal fills the mold cavity thoroughly before solidification. Their relatively low melting point also means less energy is needed to melt them than metals like steel or iron.

Factors Influencing Aluminum Alloy Selection for Die Casting

Several key factors should be considered when choosing aluminum alloys for die casting. These include:

  1. Material Properties: Each alloy offers a unique set of mechanical, thermal, and chemical properties, which impact the part’s performance, lifespan, and functionality.
  2. Cost-effectiveness: Different alloys may have varying costs, depending on their composition and the market availability of the constituent metals.
  3. Manufacturability: Some alloys may be easier to cast and machine than others, which can influence production speed, tool wear, and overall manufacturing costs.
  4. End-use Requirements: The intended application of the die-cast part plays a significant role in selecting the alloy. For example, alloys used for parts that require high strength or corrosion resistance may be different from those used for parts that need good thermal conductivity.



In conclusion, the selection of the right aluminum alloy for die casting depends largely on the end-use requirements, cost-effectiveness, and manufacturability. Understanding the unique properties of each alloy and how they fit into specific applications is key to successful and optimal product development.