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The Difference Between Aluminum, Magnesium, & Zinc Alloys

Alloy 380 is used in a variety of products such as home appliances, furniture, power tools, automotive parts, electronics, and lawnmower housings. Because it offers the best range of properties for both the finished product and casting, Magnesium 380, contains 8.5 percent silicon and 3.5 percent copper. That has a tensile strength of 324 megapascals or 47-kilo pounds per square inch.

Alloys 383 and 384, are more resistant to hot cracking and have better die-filling characteristics. When casting complex components, are alternatives to alloy 380.

Alloy 360 outperforms other aluminum alloys in terms of strength when subjected to higher temperatures. It is also more resistant to corrosion.

Alloy 443 has the highest ductility of any aluminum alloy, or the ability to stretch under tensile strength.

While zinc is ideal for casting thin-walled components, aluminum alloy 413 is useful for casting a wide range of intricate parts. It also provides better pressure tightness than its competitors when manufacturing hydraulic cylinders or other pressure machinery.

Alloy 390 was originally developed for automotive engine blocks because it is more resistant to abrasion and wear. Alloy 390, on the other hand, has the lowest ductility of any aluminum alloy, with an elongation of less than 1%.

Higher ductility is provided by Alloy 518, which also has excellent corrosion resistance when compared to other alloys used in casting.

Differences In Alloys

  • Aluminum Vs. Magnesium Alloys

Magnesium alloys, like aluminum alloys, are used in the casting of automotive parts. And have their own distinct mechanical and physical properties. While experiments have been conducted to substitute magnesium for aluminum. It is still softer, less stable, more expensive, and bends more easily when stressed.

While aluminum alloys take longer to solidify than magnesium alloys, they have a longer die life. Furthermore, aluminum does not necessitate as much finishing work as magnesium. When determining the application of magnesium casting, special treatments and coatings are required.

When compared to the cost of melting aluminum, according to magnesium alloys suppliers

new technology has reduced the costs of melting magnesium alloys; however, casting requires a faster injection speed.

According to the AM60B supplier, Magnesium has a faster ejection time than aluminum castings. Magnesium is also better than aluminum at casting components with thinner walls and tighter tolerances.

Despite magnesium’s numerous advantages, aluminum remains a less expensive alternative for die casting.

  • Zinc Vs. Magnesium alloys

One of the primary distinctions between magnesium and zinc alloys is that zinc and zinc-aluminum alloys require lower casting pressures and temperatures. Zinc has a much longer die life than magnesium. Due to its lower casting temperature, which can help reduce production costs.

In contrast to magnesium, which requires special treatments and coatings for corrosion resistance and finishing. Zinc alloys offer excellent corrosion resistance as well as a better surface finish when ejected from the die.

  • Zinc And Zinc-Aluminum Alloys

No other alloys compare to zinc and zinc-aluminum alloys when it comes to casting components with tight tolerances and areas with thinner wall sections. With a specific gravity of 7.0, the element is one of the heaviest materials commonly used in die casting. Zinc is ideal for high-volume miniature die casting parts using a special hot-chamber injection process.

Zinc is alloyed with other metals, like magnesium and aluminum, to improve corrosion resistance, stability, dimensional strength, and impact strength. Several zinc alloys are known as ZAMAK, an acronym for zinc, aluminum, magnesium, and copper. Zinc 3 is the most commonly used zinc alloy, and it is sometimes used exclusively by die casters due to its lower cost. Furthermore, the alloy provides a better surface finish at higher production rates while still casting stable, intricate designs and complex components.

Zinc 5 is an alternative to zinc 3 because of its higher tensile strength, hardness, and lower ductility. Zinc 7 can be used to produce a higher volume of components with thin walls because it has a higher fluidity than other zinc alloys, which may increase production rates.

The Zinc-Aluminum alloy, ZA-8, is the best choice for the highest strength and creep resistance, as well as deformation under mechanical stress. With 8.4 percent aluminum and 1% copper content, ZA-8 offers lower densities with higher wear resistance. When compared to other commonly cast alloys, zinc alloys have higher impact strength.

  • Aluminum Vs. Zinc Alloys

One of the primary differences between aluminum and zinc alloys. As with magnesium, is that zinc has a lower melting temperature and requires lower casting pressures. Zinc is thought to be the most castable of all commonly used alloys.

Because zinc has a lower melting temperature than aluminum. It can last much longer. Dies are costly and keep them in service for a longer period of time. That will provide a more cost-effective approach to high-volume casting projects.

Furthermore, the lower melting temperature of zinc enables hot chamber casting, which is less expensive than cold chamber processes. Production speed will be increased by using the hot chamber die casting method. Zinc is one of the toughest alloys available, outperforming even aluminum in terms of impact resistance.

Another benefit of using a zinc alloy over an aluminum alloy is that zinc is ideal for castings with fine details and thin walls. Because of the lower pressure and melting point, zinc requires very little machining, trimming, or finishing work because it experiences less thermal shock during casting. When casting in zinc, a smoother surface is maintained when a component is ejected from a die.


Aluminum is stronger than other alloys in projects that will be exposed to high temperatures. Zinc alloys are the best choice for designs that require a high yield strength and modulus of elasticity. Magnesium also has many advantages due to its lighter weight, and it can be used in place of aluminum for certain components.

Contact the best-engineered products websites online to learn more about aluminum alloys and how they and other materials might work for your die-casting project. 

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