Primary aluminum

HPDC Alloys for Structural Casts

in Vehicle Construction
RHEINFELDEN ALLOYS
Table of contents RHEINFELDEN ALLOYS –
Ductile HPDC Aluminum Alloys
for Automotive Structural Applications

General 2 RHEINFELDEN ALLOYS GmbH & Co. KG

3 Customer support and R & D
4 – 5 Aluminum casting alloys

Alloys 6 – 11 Silafont ®-38 (Sf-38) – AlSi9MnMgZn

12 – 13 Castasil ®-37 (Ci-37) – AlSi9MnMoZr
14 – 17 Castasil ®-21 (Ci-21) – AlSi9SrE
18 – 19 Magsimal ®-59 ( Ma-59) – AlMg5Si2Mn
20 – 25 Magsimal ®-plus (Ma-plus) – AlMg6Si2MnZr
26 – 35 Castaduct ®-42 (Cc-42) – AlMg4Fe2

Technical information 36 – 37 Profile of the alloys for the die-casters

38 – 44 Technical Informations / Processing datasheets
45 – 52 Technical informations
52 Disclaimer and imprint

1
RHEINFELDEN ALLOYS GmbH & Co. KG

“Progress by tradition” Products of RHEINFELDEN ALLOYS can be found wherever

ALUMINIUM RHEINFELDEN Group: This history of aluminum steel designs or iron casts can be replaced by light aluminum
in Germany started at Rheinfelden. In 1898 Europe’s first casts. RHEINFELDEN ALLOYS is a powerful partner, especially
river power station brought about the establishment of the first to the automotive and mechanical engineering sectors in provid-
aluminum smelter in Germany, at Rheinfelden, Baden. ing alloys designed to the process and cast part based on the
The company has always operated in three business segments customer’s particular needs. We also offer papers like this hand-
and in October 2008 restructuring turned ALUMINIUM book about favorable alloys for designers of structural die-casts.
RHEINFELDEN GmbH into a holding company and independent www.rheinfelden-alloys.eu · Tel. +49 7623 93 490
GmbH & Co. KGs.
www.alurheinfelden.com We offer customized alloys and new solutions for high perfor-
mance materials and light weight components with focus on
Our policy low carbon foot print products. In this mood we developed new
RHEINFELDEN ALLOYS GmbH & Co. KG: Our innovative high strength die-casting alloys and an innovative alloy family for
character is what allows us to adapt rapidly to fast changing mar- structural casts in the automotive industry.
ket needs. The agility of a private family owned operated company,
the central geographic location in the European casting metal Please have a look to our alloy selecting tool:
market, the know-how and experience of our team, are factors www.rheinfelden-alloys.eu/alloytoy
making a difference for customers looking for reliable tradition and
modern innovation. Efficient and effective use of casting aluminum
is on the forefront of our new developments in materials.

It is RHEINFELDEN ALLOYS philosophy to fulfill requested

standards of quality, either ISO/IATF or VDA. Please ask for our
actual certificates or have a look at our homepage.

RHEINFELDEN-Ingot

Panoramic view of the entire RHEINFELDEN ALLOYS complex

2
R & D and Customer Support

When RHEINFELDEN ALLOYS develop new materials we always aim to achieve efficient and
specific use of aluminum casts. Through the use of materials, tailored and refined to increase
performance, RHEINFELDEN ALLOYS is constantly striving to help reduce vehicle weight
and therefore cut emissions. We run development projects with the goal to optimise the mech-
anical and casting properties of our aluminum HPDC alloys. Our recent developed alloys are
Silafont-38, Magsimal-plus and Castaduct-42.

RHEINFELDEN Customer Support and RHEINFELDEN TechCenter

Every product and every customer has individual requirements of the material. The Customer
Support Team at RHEINFELDEN ALLOYS has the job of anticipating these needs and producing
tailored materials, fitting the casts and your requirements. Please contact our Customer Support
Team and use our TechCenter installations at RHEINFELDEN ALLOYS also for your foundry
concerns. We can advise on the use and design of casts and the choice of alloy. Use our experience
for your success as RHEINFELDEN ­ALLOYS customer.

RHEINFELDEN alloys globally

Our development of special HPDC alloys results to patents for Castasil-21, Castasil-37,
Magsimal-59, Magsimal-plus and pending patents in 2017 for Castaduct-42 and Silafont-38.
Our license partners produce these alloys globally, especially DUBAL in Dubai, NIKKEI NMA
in North America and also in China.

In this cooperation all here described alloys are available globally. Please ask for a possibility of
local production by our partners.

3
Alloys for Structural Casts by RHEINFELDEN ALLOYS

Structural components
Casted structural components are mostly large, but always stability
defining parts. They fulfill the idea of lightweight by dimensional
stability and functional integration. In the case of a crash high energy
absorption is recommended.

Dimensional stability is during the production process positively influenced by

• Easy castability
• Suitable die-cast design
• High strength achieved without heat treatment

RHEINFELDEN ALLOYS, as alloy producer support the use of

casted structural components and developed several HPDC
alloys for that purpose. Silafont-36, Castaman-35 as AlSi10MnMg
alloys are established since years. This handbook summarizes
the new alloys for structural casts.

HPD C ALLOYS FOR

S
STR UCT URA L APP LIC ATI ON Quick finder for selecting the right alloy
• Silafont-36, AlSi10MnMg The following table provides an overview of RHEINFELDEN
• Silafont-3 8 ALLOYS’ new alloys. The existing alloys are described in

• Castasil-37 former handbooks in detail. The new alloys were developed

for structural, cases and chassis components as well as
• Magsimal-59
for battery, electric motor and high-voltage applications in
• Magsimal-plus
the field of E-mobility.
• Castaduc t-42
odising

cation
per ties
Strength in as-cast state

ctility
ng

T6
nical an
Structural application

ch riveti
Electrical application

re appli

heating
llowing

after lo echanical pro

uctivit y

ess  /  du
nce

ation
HPDC castability

tF
n resista
for tech

for pun

abilit y fo

mperatu
ll applic

abilit y a
a l cond

ng-time
toughn

abilit y
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ilit
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m
Corrosio
Suitable

Suitable

Thin wa
Electric

Weldab
Hardne

High te
Machin

Machin
Elonga

Flange
Impact

Stable

Chemical
Alloy denomination

Silafont-38 AlSi9MnMgZn – –

Castasil-37 AlSi9MnMoZr – – –

Castasil-21 AlSi9SrE – –

Magsimal-59 AlMg5Si2Mn – – –

Magsimal-plus AlMg6Si2MnZr – –

Castaduct-42 AlMg4Fe2 – – –

excellent good poor

very good all right — not applicable

4
Silafont ® – an infinite wealth of properties

A family of materials which can be adapted to the part specifications and to the customer’s
individual production process with ultimate precision. Can be easily processed, outstanding flow
properties, is modified with strontium to further enhance properties. Silafont is for complex,
delicate components which have to satisfy precisely defined requirements and, if they feature
the right components, make maximum production efficiency possible. Silafont emulates flowing
water that flows around every stone and fills every cavity. > page 6 – 11

Castasil ® – large surface, high dimensional stability, fantastic to cast

An alloy, produced for large HPDC structural parts in the automotive industry. In the meantime
several OEMs recognized the advantages of these alloys for car structural or electrical
applications: high dimensional stability, can be used without heat treatment, shape well and
easy to weld, or by Castasil-21 with highest electrical or thermal conductivity.
Nature’s equivalent: the vine shoot which turns towards the sun, flexible, elastic and yet
incredibly tough and strong. > page 12 – 17

Magsimal ® – of filigree lightness, but extremely resilient

An alloy family for delicate parts which need to retain their strength and precise form
over a long period. Good weldability, high resilience, can be used in virtually any application.
Supreme c­ orrosion resistance, even to salt water.
Parts which simulate the structure of the wings of a dragonfly: wafer thin, elastic and yet
offering incredible strength and resilience, they enable this dainty insect to fly distances that
never cease to amaze. > page 18 – 25

Castaduct ® – Always fascinating pliable down to the finest detail

An innovative HPDC alloy family also for large-area components like structural casts in
thin-walled design. Modern lightweight construction is easy to realize thanks to excellent cast-
ability, use in the as-cast state and a smart alloy composition with its low specific weight,
even for higher temperature applications in battery housings of the E-cars.
The temperature-loving Emerald lizard produces the same fascination with her long flexible
body > page 26 – 35

5
 Silafont®-38 (Sf-38)
An infinite wealth of properties

Example of use

The HPDC alloy Silafont-38 was developed by RHEIN- Additionally Silafont-38 has also following properties re-
FELDEN ALLOYS to further increase yield strength quired for the pressure die-casting process:
compared to Silafont-36 without significant change in •e
 xcellent castability even with varying wall thicknesses
ductility. •n
 o sticking to the mold; the low-iron Silafont-38 is there-
fore alloyed with manganese and strontium
Several hardening elements are alloyed in defined ranges in • excellent machinability
the Silafont-38. That’s the cause why the advantage is with
a T6 heat treatment. The first step – solutionizing – is still In more and more applications, mainly in car manufacturing,
necessary, but the cooling may differ. other properties of Silafont-38 are of increasing importance:
• good corrosion resistance due to specially balanced
Even with an air quenching to lower distortion the complex composition
alloyed Silafont-38 reaches 180 MPa yield strength after • high fatigue strength and crash performance due to
artificial aging. reduced effect of disturbing Fe and Si phases
• excellent weldability for aluminum profile – cast designs
Besides these moderate cooling rates it is possible to • suitable for self-piercing riveting
cool down with water after the solutionizing treatment
to achive highest strength.

afo nt- 3
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6
Silafont ®- 38 [ AlSi9MnMgZn ]

Areas of use
Light-weight car body structures for vehicles, gearboxes, battery housings mechanical engineering.

Chemical composition of Silafont-38 in the ingot [ % of mass ]

[ %] Si Fe Cu Mn Mg Zn Ti Zr others

min. 8.5 0.1 0.4 0.3 0.1 0.1

max. 10.0 0.15 0.4 0.8 0.4 0.3 0.15 0.3 Mo; Sr

Mechanical properties

Casting Treatment Quenching YTS UTS Elongation

method state cooling Rp0.2 [MPa ] Rm [  MPa  ] E [  % ]
HPDC F 135 – 160 270 – 300 4 –8
HPDC T6 Water 230 – 280 300 – 350 6 –9
HPDC T6 Air 180 – 210 250 – 290 8 – 11

Physical data

Density Coefficient of thermal Thermal Conductivity ElectricalConductivity Shrinkage

[ kg/dm3 ] expansion [ 1/K × 10 -6 ] [W/(K ×  cm)] [ % IACS ] [ %]
2.69 21 1.5 36.0 – 41.5 0.4 – 0.6

KEY FIGURES of Silafont-38

• Further development of the well-known Silafont-36 for the use in ultra-high strength
and crash-relevant structural parts in the automotive industry.
• Complex alloyed Primary Aluminum HPDC alloy with low Fe content.
Also a Strontium permanent modification for very high elongation with good ductility.
• Low distortion T6 heat treatments with cooling in moving air could be realized
(Cooling rate after solution treatment: at least 3 °C/s down to 200 °C).
• E xcellent dynamic fatigue strength.
• Very suitable for applications in vehicle designs.
Heat treatable to high elongation and high energy absorption capability.

• Replaces steel sheet constructions in vehicle designs. •E

 xcellent castable HPDC alloy: Solidification range,
• Allows weight reductions of up to 40 % compared to die- shrinkage behavior and expected mold endurance
casting standard alloys in the field of vehicle structural parts. are comparable to that of AlSi9 and AlSi10Mg alloys.
• E xcellent machinable and very good suitable for all •B
 est mold release: No sticking to the mold.
welding processes. • Excellent castable for casts with wall thickness above 1.5  mm.
• Very suitable for riveting with applicable riveting processes
and tools.
• Very good corrosion resistance:
Coatings may be unnecessary.

7
Silafont ®- 38 [ AlSi9MnMgZn ] – Properties

[ %] Si Fe Cu Mn Mg Zn Ti Zr others

min. 8.5 0.1 0.4 0.3 0.1 0.1

max. 10.0 0.15 0.4 0.8 0.4 0.3 0.15 0.3 Mo; Sr
Tab. 1: Chemical composition of Silafont-38, AlSi9MnMgZn in the ingot (in mass-%)

Requirements for lightweight construction with the aim of higher to a lesser extent also by zinc. Magnesium in an alloy range of
strength for thin-walled designs in structural casts are constantly 0.28 to 0.35 % allows a good increase in T6 strength, even if this
increasing. The potential of Silafont-36, the structural alloy process is performed as a low-distortion variant in the air stream.
known worldwide as the standard, continues to be exploited, Molybdenum is dissolved in the α-crystal of aluminum and forms
especially by optimizing the die-casting and heat treatment no detectable by light microscopy phases. Nevertheless, this al-
processes. RHEINFELDEN ALLOYS has achieved a further in- loying increases strength starting from a content of 0.10 %.
crease through an alloy engineering development in conjunction In contrast, zircon has a content of 0.10 % as a strength-enhanc-
with a low-distortion heat treatment method with the Silafont-38 ing grain refiner.
described here.
The set in close tolerances levels of magnesium and copper give
Alloy description in this ratio a good corrosion resistance, since so the formation
In the development of the alloy Silafont-38, particular atten- of corrosion-promoting intermetallic phases is not promoted. Al-
tion was paid to the castability (Tab. 1). Generally, castability is though higher levels of Cu would lead to an increase in the yield
comparable to a Silafont-36. The wider solidification interval due strength, but worsen the corrosion behavior.
to the higher concentration of copper and zinc even increases the
mold filling capacity. A further reduction of the silicon would in- Modification
crease the elongation, but then reduces the very good flowability. The modification of the AlSi eutectic is achieved by the addition
of strontium (Sr) and favors a very fine, coral-shaped solidification
The sticking tendency is reduced primarily by the high manga- of the silicon in the eutectic. This refinement is achieved in die-
nese content, but also by iron and strontium. In this AlSi alloy, the casts of Silafont-38 with a Sr content above 80  ppm.
Mn content crystallizes in hexagonal Al6Mn intermetallic phases; Above a level of 350  ppm Sr, the general tendency of the melt
a crystal form that allows high deformations of the cast, since to oxidize increases, which would lead to an increased hydrogen
there are no serious sharp edges in the microstructure of the content of the melt. This should be considered in structural casts
casting alloy. Several casting tests confirmed the good castability for welded assemblies, as this is also a cause of weld porosity.
of the Silafont-38. Metallurgically, only a Sr content above 450  ppm leads to the
formation of coarser, moreover Mg-containing mixed crystals, that
The increase in strength through a T6 heat treatment is achieved is to say for over-refinement. A reduction in elongation can then
primarily by intermetallic phases with magnesium, copper and be seen as well.

100   µm 100   µm

Fig. 1a: M
 icrostructure of Silafont-38, AlSi9MnMgZn, in the as-cast state, Fig. 1b: Microstructure of Silafont-38, AlSi9MnMgZn, in the T6 state
3 mm sample plate

8
 Silafont ®- 38 [ AlSi9MnMgZn ]

Metallography and phase simulation has an effect on material properties. The achievable strengths,
In Fig. 1a, metallographic microstructures from the die-casted especially at the yield strength, increase considerably. For this
alloy are shown in 500-times magnification. In condition F, a very reason, a heat treatment installation has been built up which ap-
fine eutectic can be seen, which allows a very high deformability proximates the quenching conditions of an industrial production.
already in the as-cast state. Intermetallic phases are under The quench rate was set at 3 °C/s for this laboratory method.
10 microns in size, thus very small and evenly distributed.
Fig. 3 shows temperature curves of 3  mm plates at different
The solidification of Silafont-38 starts with the Al6Mn-containing quenching conditions. Clearly, the rapid temperature cooling
phase at about 600 °C. Essential for the alloy, however, is the when immersed in water can be seen. After removal from the
formation of the modified Al-Si eutectic at 550 °C. A fine distribu- oven, the onset of cooling only delayed by 8 seconds. The
tion of the AlMnFeSi phase is necessary for a high ductility and different measuring curves when cooling with air are also due
is typically maintained in the die-cast structure with an Mn to the different intensity of the air flow. In terms of metallurgy,
content of between 0.4 and 0.8 %. The intermetallic Zr phases it is important to cool down to around 200 °C, below which the
also influence a fine structure of the Silafont-38. cooling may then proceed more slowly.

For strength, submicroscopic precipitates in the Al solid solution With this determination, material characteristics such as Tab. 2
are essential. Such precipitates can be calculated using a phase and Fig. 4 could be measured on test plates in the TechCenter.
simulation. Fig. 2 shows the metastable MgSi phases, which These are comparable to those from typical industrial production
decisively influence the strength. For their shape, the initial state processes.
of the material produced by the casting process, the solution
annealing and the quenching condition is important. If they have Silafont-38 can also be cooled down after solution annealing
a suitable size, they lead to high strength of the casting material. with a considerably faster air cooling, as well as with the special
water-polymer cooling Aluquench®. The material characteristic
Heat treatment values are shown as the mean value of about 50 samples each
In the TechCenter Rheinfelden die-casted plates of dimension in Tab. 3. The respective increase of the yield strength from the
200  ×  60  mm are poured and T6 heat treated (Fig. 1b). An ad- solution annealed state follows the higher cooling rates of these
justment of the material characteristics achievable on 3  mm test processes.
plates with large-area structural casts took place. The mold filling Typically, with faster cooling, the distortion increases due to
of these panels resembles that of high-quality cast large struc- higher residual stresses. Only the water-polymer cooling of the
tural casts more than might be expected. A significant difference Silafont-38 achieves maximum strength without significant
is the quench rate after removal from the mold or after the heat distortion. With water cooling, there is always a higher distortion
treatment. Small plates can quench significantly faster, which of the structural cast geometry.

600

500
Air
Temperature [°C]

400
Q_Prime Mg2Si
300
β" Air flow
β_Prime
200
B_Prime Water HISAQ
100

100 °C/min 10 °C/min

0
0 50 100 150 200 250
Time [s]

Fig. 2: Calculated phase diagram for the time temperature curves of the different Fig. 3: Cooling curves with different cooling agents at 3 mm HPDC plates
MgSi precipitations in Silafont-38

9
Silafont ®- 38 [ AlSi9MnMgZn ] – Properties

Casting Method Treatment Quenching YTS UTS Elongation

state cooling Rp0.2 [MPa ] Rm [  MPa  ] E [  % ]

HPDC F 138 299 8.4

Standard deviation 3 8 0.8

HPDC T5 Water 220 317 6.2

Standard deviation 4 7 0.3

HPDC T6 Air 3  °C/s 192 264 10.5

Standard deviation 9 7 1.4

Tab. 2: Mechanical properties of Silafont-38, AlSi9MnMgZr plates in comparison F to T5 water cooled and T6 air cooled;
the standard deviation is calculated of 50 casts

350
T6
Water
300
F
T6
250
Air
Stress R [MPa ]

200

150

100
Temper F Temper T6 Water Temper T6 Air
YTS = 147 MPa YTS = 272 MPa YTS = 185 MPa
UTS = 290 MPa UTS = 344 MPa UTS = 278 MPa
50
E = 5.5 % E = 6% E = 10 %

0
0 2 4 6 8 10 12

Elongation E [ %]

Fig. 4: Stress-strain curve for Silafont-38, AlSi9MnMgZr, as-cast state and T6 cooled with air or water

Casting Method Treatment Quenching YTS UTS Elongation

state cooling Rp0.2 [MPa ] Rm [  MPa  ] E [  % ]

HPDC F 138 299 8.4

HPDC T6 Air 3 °C/s 192 264 10.5

HPDC T6 Air > 10 °C/s 209 288 11.0

HPDC T6 Aluquench 257 332 10.0

HPDC T6 Water 272 344 6.0

Tab. 3: Mechanical properties of Silafont  38, AlSi9MnMgZn in the T6 state and with different cooling agents

10
 Silafont ®- 38 [ AlSi9MnMgZn ]

This shows the importance of the high alloy content in the Corrosion resistance
Silafont-38 in order to achieve the requirements of mechanical A salt spray test (ISO 9227) and an intercrystalline corrosion test
properties with minimal component distortion. (ASTM G110-92) were performed at external laboratories. The
corrosion behavior of 3  mm sheets of Silafont-38 in this case was
Short-term and long-term stability compared with that of Castasil-37, AlSi9MnMoZr.
Aging of the casts is tested by testing at 205  °C for 1 hour and The corrosion-influencing difference to this alloy is in the higher
at 150 °C for 1000 hours. Thereafter, the mechanical proper- levels of Cu and Zn, as well as Mg in the Silafont-38.
ties of the components made of Silafont-38 must not have fallen The evaluation after 336 hours of spray test revealed a similar
below the specifications of mechanical strength. corrosion resistance of the two alloys. One difference was in the
Silafont-38 has passed this after heat treatment with the air nature of the corrosion attack. Castasil-37 as a high-purity alloy
quenching used here at 3 °C/s after solution annealing. tended to pitting corrosion, while the zinc and copper fractions
of Silafont-38 were more likely to cause areal corrosion.
Rivetability
The strength of a material affects the rivetability. Materials Case study
with higher strengths must be joined with other rivets than A HPDC test was also carried out on the structural casts as in
materials with low strengths. For this reason, the rivet geometry Fig. 6, which is installed as a door frame reinforcement of a
and parameters of the die-casting alloy Silafont-38 have been convertible. It is characterized by high strength requirements for
adjusted. The high deformability of the Silafont-38 led to crack- the crash-relevant components with a wall thickness of up to
free riveted joints. 2.1  mm. The aim was to top yield strength of 180 N/mm² with at
least 8 % elongation.
Weldability
In addition to high material parameters, good weldability is re- This sophisticated component has been previously die-casted
quired for structural casts. in series in the alloy Silafont-36 with Mg 0.35 % with a T6 heat
treatment with water quenching after solution annealing.
To check the weldability, a production-accompanying, manually With unchanged pouring parameters, Silafont-38 was changed
executed welding test can be carried out. Such a test result with to a T6 heat treatment with air-shower quenching after solution
Silafont-38 is shown in Fig. 5 compared to the standard Sila- heat treatment.
font-36 alloy. Both results are far beyond the requirements.
With the help of a vacuum-assisted casting technology, the struc-
tural casts (Fig. 6) was casted in a “double cavity” mold. The char-
acteristic values from Tab. 2 were achieved in the as-cast condition.
Further, the T5 condition was achieved by quenching in water after
casting. Cooling after solution heat treatment at T6 was performed
by an air shower at 3 °C/sec. These are averages of about 50
tensile bar samples; the standard deviations is also given.

Fig. 5: Welding beam on tested structural part, Silafont-36 (left) and Silafont-38 (right) Fig. 6: Door frame reinforcement, Silafont-38 T6 Air quenched

11
 Castasil ®-37 (Ci-37)
Large areas, high dimensional stability, fantastic to cast

Example of use

Development by RHEINFELDEN ALLOYS Castasil-37 Specially chosen chemical composition enables the
shows good mechanical properties, especially elongation, following casting properties:
which are superior to those of conventional AlSi-type •e
 xcellent castability
alloys. Out-standing castability and weldability enable the • suitable for minimum wall thicknesses
casting of complex designs. Self-piercing riveting trials •n
 o sticking to the mold
in the as-cast state led for example to good results.
With increasing number of applications, mainly in car
The properties are mainly influenced by alloying with silicon, manufacturing, other properties of Castasil-37 became
manganese, molybdenum and strontium. A low magnesium also important:
content is essential for the excellent stability of long-term •h
 igh fatigue strength
stability of mechanical properties. • very good corrosion resistance
•e
 xcellent weldability
• excellent machinability
• s uitable for self-piercing riveting
• s uitable for adhesive bonding applications

f C i- 3 7
URES o se s
K E Y F IG thicknes
r d if fe rent wall lSi-alloy
s
• suitable
fo
c o m p ared to A
strength
t fatigue
• highes nc e
n resista -c ast
g o o d corrosio b ilit y in as
• very n a l s ta
imensio
g , bes t d lic ations
• no agin e b o n ding app
s iv
for adhe
• suitable

12
Castasil ®- 37 [ AlSi9MnMoZr ]

Areas of use
Connection nodes for space frame designs; thin-walled body parts; architecture, cars, lighting, aircraft, domestic appliances,
air conditioning, automotive engineering, foodstuffs industry, mechanical engineering, shipbuilding, defence engineering;
replaces high pressure die-casts with T7 or T6 with air quenching.

Distinguishing characteristics
HPDC alloy with excellent castability. Very high elongation in as-cast state as a result of which it can be used in more ways
when in as-cast state. Further increase in ductility thanks to single-stage heat treatment. No distortion or blisters from solution
heat treatment, very good corrosion resistance, no long-term ageing due to heat, good machinability, ideal for riveting and
adhesive bonding in automotive engineering.

Chemical composition of Castasil-37 in the ingot [ % of mass]

[ %] Si Fe Cu Mn Mg Zn Mo Zr Ti Sr others

min. 8.5 0.35 0.1 0.1 0.006

max. 10.5 0.15 0.05 0.6 0.06 0.07 0.3 0.3 0.15 0.025 0.10

Mechanical properties

Wall thickness YTS UTS Elongation

[ mm ] Rp0.2 [MPa ] Rm [  MPa  ] E [  % ]
2–3 120 – 150 260 – 300 10 – 14
3–5 100 – 130 230 – 280 10 – 14
5–7 80 –  110 200 – 250 10 – 14

Physical data

Density Coefficient of thermal Thermal Conductivity ElectricalConductivity Shrinkage

[ kg/dm3 ] expansion [ 1/K × 10 -6 ] [W/(K ×  cm)] [ % IACS ] [ %]
2.69 22 1.4 31.0 – 38.0 0.4 – 0.6

Wöhler's diagram for Castasil-37

F Stress ratio r = -1
200
4  mm wall thickness, form factor K t = 1.2
180 5 %, 50 %, 95 % fracture probability
160
Stress R [MPa]

140
Stress R [MPa]

120
100 95 %

80 50 %
Temper F 5%
YTS = 125 MPa 60

UTS = 277 MPa 40

E = 14.9 % 20
0
104 105 106 107 108

Elongation E [ %] Number of load cycles [n]

Stress-strain curve for Castasil-37, AlSi9MnMoZr, in the as-cast state (F) Wöhler’s diagram for Castasil-37, AlSi9MnMoZr, in the as-cast state (F)

13
 Castasil ®-21 (Ci-21)
Large areas, high dimensional stability, fantastic to cast

Example of use

Castasil-21 is a HPDC alloy developed by RHEINFELDEN The specially chosen chemical composition results in
ALLOYS for casts with outstanding requirements in terms following casting properties:
of electrical or thermal conductivity. •e
 xcellent casting ability with good ejectability
Aluminum 99.7E for rotors has indeed higher electrical •w
 ell usable for thin wall fins
conductivity, but in praxis you need lower contraction for
huge casts, like with an alloy with more than 8 % silicon. More and more applications either in car design or in
telecommunication area need also following properties:
The application of Castasil-21 may help to lower the weight • v ery good corrosion resistance to weather
of HPDC, especially for the light weight design of cars •g
 ood mechanical strength compared to Al for rotors
with their additional casts like battery housing, conductor • excellent machinability
plate for electronics, LED-lighting, but also for general • fl
 angeable or deformable to fix parts together
purposes of heating and cooling. • suitable for adhesive bonding applications
•e
 lectrical conductivity comes up to 48.5 % IACS,
Chemical composition was optimized in order to have high to substitute Cu in the idea of light weight design or
conductivity (up to 30 %) compared with usual HPDC Al 99.7E in rotors
aluminum alloys and still around 10 % higher than with
Silafont-36.
-21
C a s ta s il
F IG U R E S of
KEY wall fins
ll u s a b le for thin e to weath
ering
• we is ta n c
sion res achinab
ilit y
od corro ellent m
• very go th ; e x c
al streng % IACS ,
echanic p to 48 .5
• good m o m e s u
ht desig
n
vit y c ght weig
c tr ic a l conduc ti e a o f li
• ele in the id
tute Cu
to substi rs
E in roto
or Al 99.7

14
Castasil ®- 21 [ AlSi9SrE ]

Areas of use
Also for all kind of casts with requirements in terms of high thermal or electrical conductivity. Conductor plate for electronics,
automotive and mechanical engineering, LED-lighting, air cooling, electronic boxes or covers, E-mobil applications, inclusive
electric engines.

Chemical composition of Castasil-21 in the ingot [ % of mass]

[ %] Si Fe Cu Mn Mg Zn Ti Sr others

min. 8.0 0.5 0.01

max. 9.0 0.7 0.02 0.01 0.03 0.07 0.01 0.03 0.10

Mechanical properties

YTS UTS Elongation Brinell hardness

Temper
Rp0.2 [MPa ] Rm [  MPa  ] E [  % ] [ HBW  ]
F 85 – 100 200 – 230 6 –   9 55 –  70
O 80 –  100 170 – 200 9 – 15 55 –  65

Physical data

Density Coefficient of thermal Thermal Conductivity ElectricalConductivity Shrinkage

[ kg/dm3 ] expansion [ 1/K × 10 -6 ] [W/(K ×  cm)] [ % IACS ] [ %]
2.69 22 1.9 43.0 – 48.5 0.4 – 0.6

KEY FIGURES of Castasil-21

• Very good electrical conductivity: 25 to 28 MS/m (43.0 to 48.5 % IACS) in the state O
• Very good thermal conductivity: 1.6 to in the state O 1.9 W/K × cm
Annealing of casts for the state O leads to the highest conductivities compared to other AlSi HPDC alloys.
• Very good corrosion resistance to water and weather. Coatings are often not necessary.

• Very good values for the elongation at state O: Elongation •W

 ell suited for casts with minimum wall thickness (from
up to 15 %. 1.5  mm).
• E xcellent machinable and very suitable for welding processes. •V
 ery low heat cracking tendency and very good release
• Suitable for crimping processes. properties.
• E xcellent castable HPDC alloy. Solidification range,
shrinkage behavior and expected die-casting mold endurance
are comparable to that of AlSi9 and AlSi10Mg alloys.
• E xisting die-casting cells for AlSi alloys must not be modified.

15
Castasil ®- 21 [ AlSi9SrE ] – Properties

[ %] Si Fe Cu Mn Mg Zn Ti Sr others

min. 8.0 0.5 0.01

max. 9.0 0.7 0.02 0.01 0.03 0.07 0.01 0.03 0.10
Tab. 1: Chemical composition of Castasil-21, AlSi9SrE in the ingot (in mass-%)

Chemical composition called modification. The relevant Castasil-21 advantage of this

Table 1 shows the Castasil-21 composition with a silicon content modification is the higher conductivity of plus 2 – 4  MS /m.
of 8 to 9 %. Thus, the processing temperature is 680 – 750 °C,
an area with typical thermal shock wear of casting chamber and Heat treatment
cavity. Strontium causes a further lowering of the eutectic point, The processing in the die-casting is characterized by a very rapid
that is the melting temperature, of about 6 – 8 °C. In die-casting solidification. Although this achieves higher strength and hard-
alloys Strontium reduces the affinity of the melt to the mold, i.e. ness, this microstructure is negative for achieving high conductiv-
the tendency to stick on, although Castasil-21 is already alloyed ity ! Casts out of Castasil-21 can even further be increased
with an Fe content from 0.5 to 0.7 %. in their conductivity by one-stage heat treatment, whereby
As an impurity in this conductive alloy are magnesium and zinc the internal stress of the cast structure is equalized then. In the
contents of more than 0.08 % and a copper content more than as-cast state a die-cast with 6  mm wall thickness may reach
0.02 %. While forming the conductivity disturbing solid solution even 25 MS/m.
phases these elements are already at lower levels, but this is A heat treatment of 350 °C for 2 h or 250 °C for 3 h provides
negligible compared to the effects from the die-casting process superior conductivity of around 28 MS/m (Fig. 2). In this state,
(Fig. 1). Not so with the manganese and titanium content. the die-casts have 83 % of the conductivity of Al 99.7E. Upon
Here a value of only 0.01  % should not be exceeded in order to the cooling of the components after the stress-relieving may
keep the conductivity high. Because Castasil-21 is produced only slowly air cooling to be made.
with primary aluminum as base, further accompanying elements
are also kept very low. Handling instructions
Cleaning and processing the melt should result in a low achieved
Electrical conductivity oxide impurity. A strontium content of 100 to 350  ppm ensures
But more important is the modification of the silicon crystal during the modification. Ingate design and die-cast parameters must be
solidification. The strontium addition causes a coralline optimized to result in a solid structure without pores, due to these
solidification structure of the Si crystal in the eutectic, the so technically disturb the conductivity. Please look for handling
instructions for details of melt preparation.
37

35 Zn 35
34
Fe 33
Si Cu 32
30 31
Electrical conductivity [  MS/m  ]

Zr 30
Ti Mg 29
28
Conductivity [MS/m]

25 27
26
25
24
20 23
22
21
20
15
Cr 19
Mn 18
17
16 F F 1h 2 h 3 h 1h 2 h 3 h 1h 2 h 3 h F
10
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 15
AlSi12(Fe) 170 °C 250 °C 350 °C Al for rotors
Content of alloying element [ %] Castasil-21

Fig. 1: R
 elationship between electrical conductivity of Al99.9 and added Fig. 2: Electrical conductivity of Castasil-21 through heat treatment of the HPDC
alloying elements

16
 Castasil ®- 21 [ AlSi9SrE ]

Heatsink for electronics box

Castasil-21; temper 0
460 × 160 × 65  mm; weight: 1.5 kg

Heat conducting housing for switching electronics in cars

Castasil-21; temper 0
160 × 200 × 55  mm; weight: 0.57 kg

Heatsink for electronic device

Castasil-21; temper O
170 × 70 × 70  mm; weight: 0.4 kg

This cast with fixed electrical divice has to diffuse

the hot spot of heat through the massive plate
and the casted fins and should lower the maximum
temperature ever.

Higher heat conductivity of the alloy results directly

in lower temperature. It is not necessary to design
longer fins or add forced air ventilation.

17
 Magsimal®-59 (Ma-59)
Of filigree lightness, but extremely resilient

Example of use

Magsimal-59 developed by RHEINFELDEN ALLOYS Specially chosen chemical composition enables the
is a widely used HPDC alloy for automotive applications. following casting properties:
This alloy type has excellent properties in the as-cast state, • v ery good castability
i.e. high yield strength in conjunction with high ductility. • suitable for minimum wall thicknesses
High energy absorption capacity, e.g. in the event of a crash. • low sticking to the mold
The fatigue strength is also higher than for conventional •e
 xcellent properties in the as-cast state
pressure die-cast alloys.
With increasing number of applications, mainly in car
Most applications are therefore safety components with manufacturing, other properties of Magsimal-59 became
high performance requirements e.g. safety-belt pretensioners, also important:
steering wheel frames, crossbeams, motorbike wheel rims, •h
 igh yield strength in conjunction with high ductility
control arm, suspension-strut brackets and other flap or • v ery high energy absorption capacity
chassis components. •e
 xcellent suitable for adhesive bonding applications
• v ery high fatigue strength
The properties of Magsimal-59 depend on the wall thickness •e
 xcellent corrosion behavior
and on cooling method after HPDC. A one step heat treat- • s uitable for self-piercing riveting
ment is suggested to compensate these differences and to
result in up to 30 % higher YTS. Air quenching would be the
best, due it excludes distortions and results in high rigidity.
al- 5 9
M ag s im igh duc ti
lity
F IG U R E S of o n with h
KEY ju n c ti
The alloy Magsimal-59 is produced on a primary metal th in con
ld streng y
• high yie n c apacit ntac t
basis and therefore manifests high analytical purity.
n e rg y a bsorptio a water co
h ig h e it h s e
• very en w
This produces as a consequence outstanding mechanical ength ev
ll e n t fa tigue str
strength and an excellent corrosion behavior. • exce ehavior
ll e n t c o rrosion b
• exce

18
Magsimal ®- 59 [ AlMg5Si2Mn ]

Areas of use
Architecture, cars, aircraft, domestic appliances, air conditioning, automotive engineering, foodstuffs industry,
mechanical engineering, optics and furniture, shipbuilding, chemical industry.

Distinguishing characteristics
HPDC alloy with excellent mechanical and dynamic properties with thin walls.
Very good weldability, suited to self-piercing riveting. Excellent corrosion resistance, excellent mechanical polishability
and good machinability, ideal adhesive bonding in car body design.

Chemical composition of Magsimal-59 in the ingot [ % of mass]

[ %] Si Fe Cu Mn Mg Zn Ti Be others

min. 1.8 0.5 5.0

max. 2.6 0.2 0.03 0.8 6.0 0.07 0.20 0.004 0.2

Mechanical properties

Wall thickness YTS UTS Elongation

[ mm ] Rp0.2 [MPa ] Rm [  MPa  ] E [  % ]
<2 > 220 > 300 10 – 15
2–4 160 – 220 310 – 340 11 – 22
4–6 140 – 170 250 – 320 9 – 14
6 – 12 120 – 145 220 – 260 8 – 12

Physical data

Density Coefficient of thermal Thermal Conductivity ElectricalConductivity Shrinkage

[ kg/dm3 ] expansion [ 1/K × 10 -6 ] [W/(K ×  cm)] [ % IACS ] [ %]
2.63 24 1.1 24.0 – 27.5 0.6 – 1.1

200
320
180

160

240 140
Stress R [MPa]

120
Stress R [MPa]

95 %
50 %
100 5%
160
80

Temper F 60
80 YTS = 178 MPa Stress ratio r = -1
40
UTS = 313 MPa Wall thickness 4  mm
E = 20.6 % 20 5 %, 50 %, 95 % fracture probability

0 0
0 5 10 15 20 105 106 107 108

Elongation E [ %] Number of load cycles [n]

Stress-strain curve for Magsimal-59, AlMg5Si2Mn, in the as-cast state. Wöhler’s curve for Magsimal-59, AlMg5Si2Mn, in the as-cast state
Wall thickness of samples: 3  mm

19
 Magsimal®-plus (Ma-plus)
Of filigree lightness, but extremely resilient

Example of use

The Magsimal-plus, AlMg6Si2MnZr with an additional yield Magsimal-plus is the ultrahigh-strength AlMg die-casting
tensile strength on top to the previous Magsimal-59 was alloy for high-tech lightweight construction in the vehicle
developed in the RHEINFELDEN ALLOYS TechCenter. structure.
Our aim is to get 10 % more YTS, which means 20 MPa • a pplication in as-cast state for die-casts of 2 – 6  mm
more and may result in less wall thickness respective less wall thickness
weight of the cast. Compared to AlSi10MnMg this may be • natural hard alloy with hardening effect
even 40 % advantage in strength. With this strength even • excellent corrosion resistance against salt water
steel sheet parts maybe substituted with a die-cast and its
advantages for high functional integral design, ready in the
as-cast state.

Despite the high Mg content of Magsimal-plus extraordinary

p lu s
good corrosion behavior is recognized in our tests. g s imal-
R E S of Ma
KEY F IG U junc tion
The properties of Magsimal-plus depend on the wall thick-
s tr e n g th in con
nt yield
ness and on cooling method after HPDC. Air quenching • excelle ty
ig h duc tili short term
would be the best, due it excludes distortions and results with h c ts after
e ff e er
h e r ag in g cycle aft
in high rigidity. • no furt e .g . p a int bake
ent,
T5 treatm
c o ating
powd e r apacit y
rg y a b s orption c
h ene
• very hig havior
n t c o rr osion be g
• excell e g rivetin
fo r s e lf-piercin
itable
• well su gue stre
ng t
ig h d y n amic fati
• very h

20
Magsimal ®- plus [ AlMg6Si2MnZr ]

Areas of use
Architecture, automotive or trucks, aircraft, domestic appliances, air conditioning, automotive engineering,
mechanical engineering, shipbuilding, chemical industry, substitution of complex steel sheet designs or forgings

Chemical composition of Magsimal-plus in the ingot [ % of mass]

[ %] Si Fe Cu Mn Mg Zn Ti Zr others

min. 2.1 0.5 6.0 0.1

max. 2.6 0.15 0.05 0.8 6.4 0.07 0.05 0.3 Mo; Be

Mechanical properties with 3  mm wall thickness

Treatment YTS UTS Elongation

state Rp0.2 [MPa ] Rm [  MPa  ] E [  % ]
F 200 – 220 340 – 360 9 – 12
T5 230 – 250 350 – 380 8 – 12

Physical data

Density Coefficient of thermal Thermal Conductivity ElectricalConductivity Shrinkage

[ kg/dm3 ] expansion [ 1/K × 10 -6 ] [W/(K ×  cm)] [ % IACS ] [ %]
2.64 24 1.1 22.0 – 27.5 0.6 – 1.1

KEY FIGURES of Magsimal-plus

• Magsimal-plus is an AlMgSi high pressure die-casting alloy with excellent mechanical properties
in the stabilized as-cast state for structural parts in the BIW of vehicles.
• The high strength of Magsimal-plus enables very thin lightweight designs. A weight reduction
up to 40 % in comparison to an AlSi10MnMg design may be achieved.
• No T6 or T7 heat treatment required: Cost cutting is possible due weight reduction of the cast and
due skipping heat treatment and straightening after heat treatment’s distortion.
• E xcellent corrosion behavior.

• Advanced application range for casts in the as-cast state F. •W

 ell suitable for self-piercing riveting, clinched joints and
• Very suitable for applications in vehicle designs: Excellent adhesive bonds.
energy absorption capacity in the event of a vehicle •V
 ery high resistance to stress corrosion cracking.
crash or impact to battery trays and covers.
• Substitution of complex steel sheet designs in vehicle Keep in mind:
designs is possible. • The casting of Magsimal-plus requires special know-how
• Substitution of aluminum forgings in vehicle designs is possible. in the field of mold design, melting and casting technique.
• E xcellent weldable, welding technique should be similar to
5000-series.

21
Magsimal ®- plus [ AlMg6Si2MnZr ] – Properties

[ %] Si Fe Cu Mn Mg Zn Ti Zr others

min. 2.1 0.5 6.0 0.1

max. 2.6 0.15 0.05 0.8 6.4 0.07 0.05 0.3 Mo; Be
Tab. 1: Chemical composition of Magsimal-plus, AlMg6Si2MnZr in the ingot (in mass-%)

Chemical composition effect on the formation of the Al-Mg2Si eutectic and thus ad-
Table 1 shows the chemical composition of an ingot for the versely affects the ductility.
complex alloyed Magsimal-plus, AlMg6Si2MnZr. At the die-cast,
the Fe, Cu and Zn contents mentioned here as further elements Alloy melts of Al-Mg types with magnesium content above 2 %
may be slightly higher. are tend to increased dross formation when the melt is hold in
the furnace for a long time and the melt temperature is particu-
With this development, RHEINFELDEN ALLOYS offers an larly high. Therefore, oxidation-inhibiting alloying ingredients
AlMgSi die-cast alloy with particularly high mechanical strength are added to the Magsimal-plus in the range of few 0.001 %
combined with high elongation, achievable even in as-cast con- by weight. This causes the oxide skin to become denser and to
dition. The Zr and Mo contents serve this purpose as well, which oxidize less magnesium at the melting bath surface.
increase the strengthening in the as-cast state by precipitation
hardening to SiZr and Al12 (Mn,Mo), shown in Fig 1. The thermal analysis of the Magsimal-plus is shown in Fig. 2. The
temperature curve was recorded with a Quick-Cup sand crucible.
The magnesium-silicon ratio ensures good castability and good The liquidus temperature is about 615 °C and the solidus tem-
feeding during solidification. The eutectic fraction in the micro- perature is about 590 °C. Here the Al-Mg2Si eutectic solidifies.
structure is about 40 %, which is sufficient for processing into
complex casts. Magnesium is present in a deliberately high sur-
640
plus, based on the compound Mg2Si. This is important because [°C]
630
it must be ensured that there is no free silicon in the structure, TG = 670.0
620
TLu = 611.3
which has negative influence to corrosion behavior. 610
Temperature [°C]

TLo = 615.1
Furthermore, the targeted high-alloyed magnesium content en- 600 dTL = 3.8
TSu = 592.6
sures the high yield strength. 590
TSo = 593.0
580 dTS = 0.4

The abundant calcium and sodium found in melting flux must be 570
560
kept low, as these elements generally negatively affect casting
550
behavior and, in particular, increase the tendency of hot cracking.
540
The phosphorus used to inert graphite must also be kept as low 0 2.5 5.0
Time [min]
as possible, because this element has a particularly negative
Fig. 2: Thermal analysis of Magsimal-59, AlMg5Si2Mn, in a Quick-Cup-Crucible

Fig. 1: C
 alculated phase diagram for main precipitations during solidification of Fig. 3: M
 icrostructure of Magsimal-plus, AlMg6Si2MnZr; 3 mm plates;
Magsimal-plus, AlMg6Si2MnZr magnification 1000x

22
 Magsimal ®- plus [ AlMg6Si2MnZr ]

The microstructure of the HPDC as shown in Fig: 3 is character- effect), which leads to a very short-term and small stress drop
ized by a uniform distribution of the Al6Mn phase. Manganese in the stress-strain curve. Fig. 4 shows a typical example of such
prevents sticking in the die-casting mold. Around the α-dendrites, behavior.
the eutectic is distributed between α-aluminum and Mg2Si.
There are no coarse phases in the overview and the eutectic is The mechanical properties of the Magsimal-plus also depend on
very fine and spherical; therefore, this is a very ductile structure. the wall thickness respectively on the solidification conditions.

Mechanical properties in the as-cast state Table 2 shows the mechanical properties in the as-cast state and
For Magsimal-plus, AlMg6Si2MnZr a characteristic material after T5 heat treatment. The mechanical properties shown were
property is found in the quasi-static testing of AlMg alloys. The determined on vacuum assisted sample plates and samples of
tensile test shows small spikes in the stress-strain curve. These structural die-casts with a wall thickness of 3.0  mm.
are not cracks in the material, but it is the so-called strain aging. In addition, the aging at room temperature has to be considered,
This phenomenon occurs in the plastic range of the stress- which occurs in thin-walled, natural hardening Magsimal-plus die-
strain curve. It is an interaction between dissolved atoms and casts after demolding and water-quenching.
migratory dislocations in the microstructure (Portevin-Chatellier
Only after 20 days or after T5 treatment is the yield strength at
400 a stable, higher level. For water-quenched casts, the strength
increases by about 30 MPa, but with the use of air quenching
350
by only 5 MPa higher. However, the elongation at break barely
300 T5 decreases.

250
It must be noted that the values in the real cast may vary de-
Stress R [MPa]

200 F pending on the proportion of pre-solidification and oxide contents

as well as the flow and solidification behavior during cavity
150 Temper F Temper T5 filling and are generally better in well-flowed cast cross-sections
with 3  mm plate with 3  mm plate
100
than in areas of cavity filling end. By connecting overflows and
YTS = 206 MPa YTS = 229 MPa
UTS = 342 MPa UTS = 359 MPa vents at correct positions this influence can be reduced. There-
50 fore, the determination of suitable positions for the removal of
E = 10.9 % E = 10.1 %
test specimens from die-casts is demanding and must be defined
0
0 3 6 9 12 in any case exactly between the foundry and the die-cast part
Elongation E [ %]
designer.
Fig. 4: S
 tress-strain curve for Magsimal-plus, AlMg6Si2MnZr in the as-cast state (F)
and temper T5

Casting Method Wall Numbers of Treatment YTS UTS Elongation

thickness test pieces state Rp0.2 [MPa ] Rm [  MPa  ] E [  % ]

TechCenter 3  mm 40 F 208 348 10.4

Standard deviation 2.8 6.5 1.4

TechCenter 3  mm 40 T5 231 363 10.0

Standard deviation 2.9 6.5 1.4

Testpart 3  mm 36 T5 239 366 10.2

Standard deviation 10.9 9.5 2.8

Tab 2: Average mechanical properties of Magsimal-plus, AlMg6Si2MnZr in the as-cast state and after T5 from test plates and typical HPDC parts

23
Magsimal ®- plus [ AlMg6Si2MnZr ] – Properties

Mechanical properties after T5 treatment The MIG pulse synergic welding machine TPS-400i from Fronius was
A further increase in strength can be achieved by a T5 treatment used with a pulsed arc process with controlled material transition.
of the cast at only 200 °C in 30 – 60 minutes. It has been indi- Thus, the workpiece surface is preheated and achieved an
cated that the cast must be quenched immediately after demold- accurately metered current pulse for the targeted detachment
ing from the die-casting mold, so that the appropriate increase in of a welding material drop. This Cold-Metal-Transfer principle
strength during artificial ageing can be achieved. Only a cooling guarantees very low-spatter welding. The particular advantage
in air after demolding does not achieve the full effect. of this connection welding is also the only slight distortion in
The increase in mechanical properties compared to the as- particularly thin-walled produced Magsimal-plus die-casts. Both,
cast state is shown in Fig. 4. These mechanical properties were outer appearance and inner weld quality were achieved with very
determined on 3.0  mm sample plates as well as on large-sized good results (Fig. 5b).
structural die-casts, designed and manufactured to suit the alloy
features. Another subordinate factor is that the Magsimal-plus, unlike
This short T5 artificial aging treatment thus significantly shortens classic AlSiMg alloys, has virtually no hysteresis in the linear
the otherwise waiting for natural aging. expansion when heated to 300 °C. It is therefore barely expected
component distortion after such heat in the environment of
In the automotive industry also demands on the short and long the weld.
term stability of the mechanical properties are made. Such aging
tests at 205 °C for 1 h or 150 °C for 1000 h, the casts from Magsi- Corrosion resistance
mal-plus has been successfully passed after short T5 treatment. AlMg alloys are usually very resistant to corrosion and are there-
fore also used in a seawater-containing atmosphere.
Weldability Since this type of alloy can also be used for structural casts in
All-aluminum constructions with structural cast application are vehicle construction, a test for determining the tendency to stress
virtually impossible without welded joints. Therefore, butt welds corrosion cracking is inevitable.
and fillet welds were tested with die-casted sample plates in the
MIG process, shown in Fig 5a. The Magsimal-plus die-cast sample Corrosion resistance was tested with an intercrystalline corrosion
plate with 3.0  mm thickness was butt-welded to AlMgSi0.5. test according to ASTM G110-92 and a salt mist spray test ac-
The welding filler material used was an S-AlMg4.5Mn welding wire cording to EN ISO 9227 and was passed with very good results.
with Ø  1.2  mm.

Fig. 5a: Cross-section of a butt-welded cast-sheet-connection Fig. 6a: Overview about the punch rivet tests with Magsimal-plus, AlMg6Si2MnZr

1,773 mm
2,049  mm
100   µm 1,008  mm
0,603  mm 0,744 mm

Fig. 5b: M
 icrograph from the welding beam section between Magsimal-plus and Fig. 6b: Cross-section of the punch rivet with some calculations
AlMgSi0.5 sheet

24
 Magsimal ®- plus [ AlMg6Si2MnZr ]

Riveting capability refining and modification agents, no phosphorus, alkali and earth
In body construction with its various materials, the connection alkali containing substances and no different metals are supplied
technology punch riveting plays a major role (Fig. 6a). In this to the melt. Because of this, the Al-Mg2Si eutectic is strongly
process semi-hollow punch rivets pierce the overhead steel or influenced and coarsened (Fig. 7b).
aluminum sheet and dig into the cast (Fig. 6b).
The casting material must be able to withstand the deformations The temperature during Magsimal-plus melting should not per-
on the closing head of the riveting mold. A further evaluation manently exceed 780 °C. The holding temperature after melting
is carried out at closely side by side placed rivets or with rivets should be set to 760 °C.
placed close to the cast’ edge in the demand for crack-free clos- In melting furnaces, which keep the melt moving with heat con-
ing heads on the casted surface. vection, the form of lids are reduced by less oxide-melt reactions
and segregations. This also applies to furnaces in which the bath
The rivet mold significantly influences the riveting result. The movement takes place by means of rotor or with purge gas initia-
semi-hollow punch riveting processes have to be optimized for tion by furnace bottom stones. Furnaces with roof heating and no
high-strength Magsimal-plus applications. Sections of the bath movement cause difficulties for longer holding time. Melting
cast intended for punch riveting should not be designed thinner of all aluminum alloys and also Magsimal-plus reacts less with the
than 3  mm to have the required ductility. refractory material, if it contains more than 85 % aluminum oxide.

Surface finishing The remelting of runners, return scrap and others is not a prob-
Magsimal-plus can be painted, powder-coated, polished or anod- lem. However, care must be taken that mixing with other alloys
ized. Polishing results into a typical slight blue coloration of the cannot take place. This would negatively affect the mechanical
surface gloss. When anodizing, it should be noted that a gray properties.
shade should be formed because of the low silicon content. For When using return material, a good melt cleaning by means of
decorative purposes, it is therefore advisable to use a chrome rotor and argon or nitrogen gas is absolutely necessary, since
layer or the polished surface. oxide inclusions, oxide skins, etc. have to be removed. These can
accumulate in the melting and casting process and exert a nega-
Melting process tive influence both on the cast properties and on the achievable
Magsimal-plus has a special long-term grain refinement particu- mechanical characteristics.
larly affecting the Al-Mg2Si eutectic. The degree of fineness of The resulting dross after cleaning and degassing cycle can be
the eutectic determines the elongation respectively the tough- reduced in their metal content with use of sodium-free dross
ness of the cast (Fig. 7a). Special alloying elements in alloy treatment flux.
production greatly reduce the oxidation of the melt, which is par-
ticularly characteristic to AlMg alloys. Agglomerations of oxides Casting process
on bath surfaces and on the bottom of the furnace are barely For further information, please refer to the information on the
formed. After rapid melting of the ingots a melt cleaning with a processing of AlMg casting alloys in the die-casting process in
gas rotor have to be carried out. The properties of Magsimal-plus the Chapters on Castaduct-42 alloy and design guidelines for
are retained if no sodium-containing treatment fluxes, no grain casts and die-casting molds.

Fig. 7a: Fine Al-Mg2Si-eutectic of Magsimal-plus, AlMg6Si2MnZr Fig. 7b: Coarse Al-Mg2Si-eutectic

25
 Castaduct®- 42 (Cc-42)
Always fascinating pliable down to the finest detail

Example of use

The Castaduct-42 from the AlFeMg alloy family, newly The high Fe content in the Castaduct-42 ensures reduced
developed in the RHEINFELDEN ALLOYS TechCenter, sticking tendency and improved die-casting mold life.
amazes both the foundry industry and the automotive indus-
try: Highest elongation in the as-cast and non-heat treated The Castaduct-42 is a natural-hard alloy and exhibits excel-
condition, along with a yield strength just achieved with well- lent long-term stability in the as-cast state, even at high
known AlSi10MnMg cast alloys with a T7 two-stage heat application temperatures.
treatment. The corrosion resistance of Castaduct-42 is excellent.
Further protection and di-electric strength may come with
The good castability in the die-casting process enables anodizing.
the production of large and thin-walled structural cast
components. Castaduct-42 can be combined with other Next to the applications for structural cast components,
materials in many ways using a variety of established joining thus the ductile Castaduct-42 also is very suitable for gen-
techniques. eral use in the e-mobility: battery cases and trays, cases
and covers for electronic components of the high-voltage
Castaduct-42 is plain and robust in its alloy composition, technology.
based on the two alloy components Fe and Mg. The
carefully co-ordinated alloy components of Castaduct-42
du c t- 4 2
S o f C a s ta
enable an easy handling in the die-casting process.
K E Y F IG
U R E struc tion
li g h tw e ight con
r
Any melt addition is completely eliminated. itable fo te
• very su -c ast sta
u c ti li ty in the as
td
• highes resistan
ce
e n t c orrosion nnec tion
• exc e ll
r e s ta b lished co
fo
ll suited truc tion
• very we in v e h icle cons
e s
techniqu

26
Castaduct®  - 42 [ AlMg4Fe2 ]

Areas of use
Large and thin-walled structural casts; connection nodes for space frame designs; battery housings, electronic covers
or shelter housings; thin-walled body parts; for architecture, cars, lighting, aircraft, domestic appliances, air conditioning,
automotive engineering, foodstuffs industry, mechanical engineering, shipbuilding, defense engineering.
Replaces typical AlSi10MnMg high pressure die-casts with O/T4/T7 treatment, but also Magnesium-based HPDC.

Chemical composition of Castaduct-42 in the ingot [ % of mass]

[ %] Si Fe Cu Mn Mg Zn Ti others

min. 1.5 4.0

max. 0.2 1.7 0.2 0.15 4.6 0.3 0.2 Be

Mechanical properties

Treatment Wall thickness YTS UTS Elongation Brinell hardness

state [mm ] Rp0.2 [MPa ] Rm [  MPa  ] E [  % ] [ HBW  ]
F 2–4 120 – 150 240 – 280 10– 22 65 – 75

Physical data

Density Coefficient of thermal Thermal Conductivity ElectricalConductivity Shrinkage

[ kg/dm3 ] expansion [ 1/K × 10 -6 ] [W/(K ×  cm)] [ % IACS ] [ %]
2.69 25 1.4 26.0 – 29.5 0.5 – 0.9

KEY FIGURES of Castaduct-42

• Castaduct-42 is an easy to handle alloy for BIW parts like structure casts.
• Innovative and plain alloy composition.
Developed on base of AlFe-eutectic composition.
• No T5, T6 or T7 heat treatment required:
Cost cutting is possible due skipping heat treatment and straightening of distortion.
• E xcellent resistance to sea water atmosphere.

• E xcellent suitable for BIW automotive structural appli- •W

 ell suitable for self-piercing rivets, clinched joints and
cations with requirements of medium strength, but highest crimping. High values of deforming in a bending test are
deformability. constantly measured. Much better than with AlSi10MnMg in
• High percentages of in-house scrap can easily be remelted. the as-cast state.
• Easy melt preparing without any modifying or grain •W
 ell weldable, with welding technique similar to 5000-series.
structure treatment. •V
 ery well suitable for anodizing, due to the low Silicon
• Very low sticking behavior in the mold, due the high content a bright surface image may be achieved.
Fe-content. • Well suitable for adhesive bonds.
• Easy castability in HPDC process, moderate casting tem-
perature, low tendency for pre-solidifications and hot cracks. Keep in mind:
• High resistance against high temperature ageing, up to • The casting of Castaduct-42 requires special know-how
350 °C no influence to the mechanical strength at RT. in the field of mold design, melting and casting technique.

27
Castaduct®  - 42 [ AlMg4Fe2 ] – Properties

[ %] Si Fe Cu Mn Mg Zn Ti others

min. 1.5 4.0

max. 0.2 1.7 0.2 0.15 4.6 0.3 0.2 Be
Tab. 1: Chemical composition of Castaduct-42, AlMg4Fe2 in the ingot (in mass-%)

Chemical Composition The Fe content of the casts in Castaduct-42 should be kept

The Castaduct-42 high pressure die-casting alloy is simple and between 1.3 % and 1.7 %. Thus, the hypereutectic alloy system is
robust in its alloy composition, based on the Al-Fe-Mg eutectic formed with the precipitation of Al13Fe4. Higher levels lead
in hypereutectic composition of the two alloying components to the formation of large and plate-like Fe-containing phases also
Fe and Mg. Iron is present in a necessary high content of about under pressure casting conditions, which reduce the elongation.
1.6 %. The magnesium content is about 4.3 %. This also occurs at slower solidification rates, comparable to sand
casting process.
For Castaduct-42, the Mg content should not fall below 4.0 %
and should not exceed 4.6 %. This is easy to handle at the A heat treatment leads to no change in the phases and can
melting and casting plant because the Mg content need not be therefore be omitted.
precisely controlled and not set to tolerances of less than 0.05 %
by weight. The tendency of Castaduct-42 to adhere to the mold is substan-
Also, a modification of the eutectic phases is omitted in this type tially reduced by the Fe content compared to low-Fe structural
of alloy. The elimination of silicon as an alloying element elimi- casting alloys. In practice, the dissolution behavior of steel in the
nates any Mg2Si precipitation hardening, i.e. the Castaduct-42 Castaduct-42 melt was halved in immersion tests.
is naturally hard and has an excellent long-term stability even at Higher mold endurance is expected and long flow paths can be
higher temperatures. achieved with small wall thicknesses.

Influence of Iron Disturbing elements of the in Castaduct-42 alloy

Fig. 2 shows the calculated constitutional diagram of Casta- However, the fine structure of the Al-Fe eutectic can only be
duct-42, AlMg4Fe2 with an given Mg content of 4.5 %. The Mg maintained if the Si content is kept below 0.2 %. Even slightly
is dissolved under HPDC conditions in the primary solidifying higher Si contents form notch-active AlSiFe phases, which result
Al-phase. Al solidifies in dendritic shape. in a reduction in elongation.
The liquidus temperature in this Al-Fe-Mg eutectic is lowered to
629 °C, the solidus temperature is 580 °C. Also Mn contents should remain low alloyed to avoid coarse and
The micrographs in Fig. 1a and 1b show the finely formed Al-Fe unfavorable solid solution phase precipitations.
eutectic. The overview shows the large proportion of the eutectic. Calcium and sodium worsen castability and cause increased hot
This ratio of eutectic to α-Al dendrites and the low processing cracking tendency and reduced elongation at break. Therefore,
temperature lead to the good casting properties. melting fluxes should be used specifically for AlMg alloys.

100   µm 20   µm

Fig. 1a: M
 icrostructure of Castaduct-42, AlMg4Fe2 in the as-cast state, Fig. 1b: M
 agnification of the Al-Fe-eutectic in the microstructure of Castaduct-42,
3 mm sample plate AlMg4Fe2

28
 Castaduct®  - 42 [ AlMg4Fe2 ]

Influence of Magnesium small spikes in the stress-strain curve. These are not cracks in
The Mg content determines the strength of Castaduct-42. The the material, but it is the so-called strain aging. This phenom-
Mg content increases the strength in as-cast condition by 60 enon occurs in the plastic range of the stress-strain curve. This
MPa compared to the binary AlFe alloy. The Mg is always dis- Portevin-Chatellier effect is an interaction between dissolved
solved in α-Al-phase, but may be present in slightly different atoms and migratory dislocations in the microstructure, which
concentrations. leads to a short-term and small stress drop in the stress-strain
A more Mg leads to higher yield strength, but also to a smaller curve. Fig. 3 shows a typical example of such behavior.
elongation. A balance of mechanical properties is achieved at
4.2 % to 4.5 %. Influence of wall thickness
In the area of common die-cast wall thicknesses from 2 to 4  mm,
A possible increase in the sensitivity for stress corrosion cracking the Castaduct-42 shows only minor variations in the mechanical
is only present above 5 % Mg content. On the other hand, a suffi- characteristics.
ciently high Mg content should allow the hypereutectic character
and thus the good casting capability. Tab. 2 shows the mechanical properties in the as-cast state F.
The mechanical properties shown were determined on vacuum
Alloy melts of Al-Mg types with magnesium content above 2 % supported HPDC sample plates with 2.0  mm wall thickness.
are tend to increased dross formation when the melt is hold in As part of testing Castaduct-42 with real structure casts, yield
the furnace for a long time and the melt temperature is particu- tensile strengths of between 120 and 150 MPa, ultimate tensile
larly high. Therefore, the Castaduct-42 oxidation-inhibiting alloy- strengths of between 240 and 280 MPa and elongations at
ing ingredients are added in the range of few 0.001 % by weight. break of 10 to 22 % were measured on tensile specimens with a
This causes the oxide skin to become denser and to oxidize less wall thickness of 2–4  mm.
magnesium at the melting bath surface. It must be noted that the values in the real cast may vary depend-
ing on the proportion of pre-solidification and oxide contents as
Mechanical properties well as the flow and solidification behavior during cavity filling
The Castaduct-42 stress-strain diagram in Fig. 3 clearly illus- and are generally better in well-flowed cast cross-sections than
trates the potential of this casting alloy. With favorable casting in areas of cavity filling end. By connecting overflows and vents
conditions, i.e. a die-casting process tailored to this type of alloy, at correct positions this influence can be reduced. Therefore, the
even better yield strength characteristics can be achieved in determination of suitable positions for the removal of test speci-
conjunction with an elongation of up to 22 %. mens from die-casts is demanding and must be defined in any
case exactly between the foundry and the die-cast part designer.
For Castaduct-42 a characteristic material property is found in
the mechanical testing of AlMg alloys. The tensile test shows
280

800 240
with 4,5 % Mg
F
Al + Liquid Liquid
700 200
Al13Fe4 + Liquid
600 160
Stress R [MPa]
Temperature [°C]

Al13Fe4 + Al + Liquid
500 120
Al13Fe4 + Al
 ,31 % Fe / 629 °C
1 Temper F
Eutectic Point
400 80 with 3  mm plate
YTS = 126 MPa
40
UTS = 260 MPa
300
E = 15.2 %
Al13Fe4 + Al13Mg2 + Al
200 0
0 1 1,6 2 3 4 5 0 4 8 12 16
Iron [ % of mass ] Elongation E [ %]

Fig. 2: Constitutional diagram of Castaduct-42, AlMg4Fe2 with 4.5 % Mg Fig. 3: S

 tress-strain curve of Castaduct-42, AlMg4Fe2 determined from 3.0  mm
flat tensile specimen

29
Castaduct®  - 42 [ AlMg4Fe2 ] – Properties

Treatment Wall thickness YTS UTS Elongation Brinell hardness

state [mm ] Rp0.2 [MPa ] Rm [  MPa  ] E [  % ] [ HBW  ]
F 2–4 120 – 150 240 – 280 10– 22 65 – 75
Tab 2: Mechanical properties of Castaduct-42, AlMg4Fe2 in the as-cast state; the typical wall thickness of the several tested HPDC are 2–4  mm

Deformation capability Castaduct-42 was always tested in as-cast condition and showed
The Castaduct-42 alloy has a very high deformability in as-cast very good results.
condition and is thus also well suited for crash-relevant applica-
tions in vehicle design. The evidence was provided in the context Welding performance
of alloy development by means of plate bending test for metallic In addition to the very good punch riveting ability, a good degree
materials, according to VDA 238 – 100 (Fig. 4) and with Erichsen of welding suitability is of great importance for the use of Casta-
cupping tests and confirmed several times by samples of real duct-42 in vehicle design.
casts. Plate bending angles of up to 60 ° are achieved. Bending
angles of more than 70 ° could be achieved with proper casting In the MIG process, Castaduct-42 die-cast sample plates 3.0  mm
conditions. These high measurement values indicate a very good were butt-welded and fillet-welded to AW-AlMgSi0.5 to test the
behavior in punch riveting and similar joining methods. weldability (Fig. 6a/6b). The welding filler material used was an
S - AlMg4.5Mn welding wire with Ø  1.2  mm.
The Erichsen cupping test is another test for the suitability of a The micrographs of the welded seams show a low-pore and finely
casting alloy for structural components in vehicle design. Here, structured microstructure, which results in homogeneous material
a sheet-like test strip from the cast is deliberately deformed to a properties in the joining zone. The silicon free welding conditions
point of first fissure by a ball lowering in the measurement setup. leads here to no significant changes in the mechanical character-
With increasing sample plate thickness the Erichsen depression istics. The right choice of welding filler material leads to crack-
decreases. For a 2.0  mm sample plate in AlSi alloy deformation free and ductile welds.
values around 3  mm are common. For the same sample plate in
Castaduct-42 the values of 4.5  mm are very high and indicate a For welded joints on aluminum sheets of the 6000 series, i.e.
high deformation capacity in the event of a crash. AlMgSi alloys, the alloy S - AlMg4.5Mn is also recommended as
the welding filler material.
In the context of alloy development, a hudge amount of punching
tests were carried out with very good results on 3.0  mm sample
plates and on samples of real Castaduct-42 casts (Fig. 5a/5b).

4000

3500

3000

2500
Fig. 5a: Rivet tests connecting steel sheet to HPDC in Castaduct-42, AlMg4Fe2
Force [N]

2000

1500
Bending test
with 2  mm plate
1000
following VDA 238  – 100
distance = 6.86  mm
500
Angle α = 56.7 °
1,574  mm
0 1,841 mm
0 2 4 6 8
Distance [mm] 0,837 mm 0,398 mm 0,311 mm

Fig. 4: Load-extension diagram of plate bending test Castaduct-42 , AlMg4Fe2 Fig. 5b: C
 rossection with calculation of the HSN rivet test in Castaduct-42,
AlMg4Fe2

30
 Castaduct®  - 42 [ AlMg4Fe2 ]

Corrosion resistance Thermal conductivity

Corrosion resistance was tested with an intercrystalline corro- The thermal conductivity of Castaduct-42 was measured on
sion test according to ASTM G110-92 and a salt mist spray test die-casted sample plates in the as-cast state F with a thickness
according to EN ISO 9227. of 2.0  mm. The samples were heated in 50 °C increments at
In the intercrystalline corrosion test, the samples are aged for 10  °C /min from 20 °C to 500 °C and back again. The conductivity
two hours at room temperature in a hydrochloric acid test solution measurement was carried out after a holding time of 60  min each
with 1000 ml H2O, 20  g NaCl and 100 ml HCl 25 %. For the salt increment (Fig. 7).
mist spray test, the samples were exposed to a defined salt mist
load for 14 days. The Castaduct-42 shows itself here with a averaged value of
140  W/(m × K) clearly unaffected by the heat input. A heat treat-
ment would thus lead to any changes in the thermal conductivity
Casting alloy IC max. depth [µm] Salt spray max. raid [µm]
and is primarily due to the absence of silicon.
Surface End wall Depth Diameter
Castaduct-42 135 90 15 200
Heat treatment
Castasil-37 235 205 150 2400
The Castaduct-42 is a naturally hard die-casting alloy and does
not require any heat treatments, since no hardening structural
The corrosion resistance of the alloys Silafont-36, AlSi10MnMg components are present. Stabilization annealing is not required.
and Castasil-37, AlSi10MnMoZr is generally considered to be Even an annealing temperature up to 350 °C results in no influ-
well-suited for structural cast applications in vehicle design. ence on the cast structure or the mechanical properties after
The corrosion resistance of the Castaduct-42 alloy can be esti- cooling.
mated as very well-suited for automotive applications.
Short-term stability / Long-term stability
Castaduct-42 has excellent aging resistance and excellent di-
mensional stability, which is due to the Si-free alloy composition.
Both the tests of the short-term stability with 1h / 205 °C and
the tests of long-term stability with 1000 h / 150 °C have been
repeatedly successfully passed.

200

190

180

170
Thermal Conductivity [W/(m × K)]

160

Fig. 6a: C
 ross-section of a welded cast-sheet-connection in Castaduct-42, 150
AlMg4Fe2 Castaduct-42 (A)
140

130
B
120

110

100
0 50 100 150 200 250 300 350 400 450 500

Temperature [°C]

Fig. 6b: O verview from the welding beam section between Castaduct-42, Fig. 7: Determination of the thermal conductivity of Castaduct-42, AlMg4Fe2 (A)
AlMg4Fe2 and AW-AlMgSi0.5; filler material S - AlMg4.5Mn compared to Silafont-38, AlSi9MnMgZn (B)

31
Castaduct®  - 42 [ AlMg4Fe2 ] – Properties

Dimensional stability Shrinkage behavior

For proof of the excellent dimensional stability of Castaduct-42 Also, the shrinkage behavior is comparable to magnesium die-
after heating, a dilatometer curve was prepared (Fig. 8). For this casting alloys and thus more pronounced than with AlSi casting
purpose two die-casted sample plates were tested. The expan- alloys. This has the consequence that the melt which is shot into
sion was 0.44 % for 20 °C to 200 °C and corresponds to a ther- the mold cavity discharges the latent heat in a shorter time to
mal expansion coefficient of 24.7 1/(K × 10 -6). the die-casting mold contour, thus solidifying in a shorter time
interval and due to the higher shrinkage factor from the liquid
The alloy Castaduct-42, unlike classic AlSiMg alloys, has no to the solid state of aggregation. Thus tends to jamming effects
hysteresis when heated up to 300 °C. on the shape of die-casting mold inserts.
The tendency to jam on die-casting mold inserts is not to be
The lack of silicon content proves to be another advantage of confused or even equate set with the sticking tendency of a cast-
Castaduct-42: There is no detectable dimensional change after ing alloy with lower Fe contents and is controllable in the casting
heat input. A possible component distortion after exposure to process with suitable measures in a simple manner.
heat is thus prevented in the best possible way.
The shrinkage behavior of Si-free or Si-poor AlMg die-casting
Application of Castaduct-42 in HPDC alloys can lead to increased micro porosity, means formation of
Generally, the Si-free die-casting alloy Castaduct-42 can be micro shrink holes due to shrinkage deficits, and also lead to
processed in established die-casting cells, with set up for the sinkholes in the area of material amassing. Sink holes occur in
production of e.g. structural parts. particular where hot spots occur in a die-casting mold together
Due to its chemical composition, Castaduct-42 has noticeably with material amassing.
lower latent heat and a somewhat higher coefficient of thermal The shrinkage of Castaduct-42 casts is slightly larger than for
expansion in comparison to conventional AlSi casting alloys and AlSi alloys and is about 0.5 % to 0.9 %.
is thus closer to the values of magnesium die-casting alloys.
The solidification interval with 635 °C liquidus and 580 °C
solidus temperature is on average 20 to 30 °C higher than with
AlSi die-casting alloys.

Design of casts
For Castaduct-42 casts, therefore, the special properties of this
innovative casting alloy must be considered both in the design of
the casts and mold design and in the design of the mold HPDC
process. More detailed information can be found in the chapter
Design guidelines for casts and die-casting molds.
0.8

0.7

0.6
Thermical expansion [%]

0.5

0.4

0.3

0.2

0.1

0.0
0 50 100 150 200 250 300
Temperature [°C]

Fig. 8: Dilatometer curve of Castaduct-42, AlMg4Fe2 after two heatings

32
 Castaduct®  - 42 [ AlMg4Fe2 ]

Melt process Melting of all aluminum alloys and also Castaduct-42 reacts
The Castaduct-42 is an AlMg-type alloy with high Fe content less with the refractory material, if it contains more than 85 %
and must not be contaminated with Si or Mn. A microstructural aluminum oxide.
modification as required with AlSi structural casting alloys is
not required. The tendency to oxidation on the surface of the The remelting of runners, return scrap and others is not a prob-
melt bath is considerably reduced by a low content of oxidation- lem. However, care must be taken that mixing with other alloys
inhibiting alloying ingredients. Agglomerations of oxides on bath cannot take place. In particular, an increase in the silicon content
surfaces and on the bottom of the furnace barely form. has a negative effect on the mechanical properties.

After rapid melting of the ingots a melt cleaning with a gas rotor When using return material, a good melt cleaning by means of
have to be carried out. The properties of Castaduct-42 are re- rotor and argon or nitrogen gas is absolutely necessary, since
tained if no sodium-containing treatment fluxes, no grain refining oxide inclusions, oxide skins, etc. have to be removed. These
or modification, no phosphorus, alkali and earth alkali containing can accumulate in the melting and casting process and exert a
substances and no different metals are supplied to the melt. negative influence on the component properties.
The temperature during melting should not permanently exceed
780 °C. The holding temperature after melting should be set The resulting dross after cleaning and degassing cycle can
to 760 °C (Fig. 9). be reduced in their metal content with use of sodium-free
treatment flux.
In melting furnaces, which keep the melt moving with heat con-
vection, the form of lids are reduced by less oxide-melt reactions Casting process
and segregations. This also applies to furnaces in which the bath The quality of the cast, with regard to the mechanical charac-
movement takes place by means of rotor or purge gas initiation teristics, the ability to deform and the weldability, is primarily
by furnace bottom stones. determined by the proportion of oxides and other impurities in
the melt and by the gases entrapped in the casts.
Furnaces with roof heating and no bath movement cause difficul- These may be due to the H2 content of the melt, residual air
ties for longer holding time without additional refilling due to the in the die-casting mold cavity, release agent residues, casting
production with AlMg alloys. piston lubricants and residuals of moisture.
Already the melt handling in the foundry can have a big influence
on the quality of the casts. A high melt temperature can lead
to increased oxidation of the melt, which on the other hand leads
to higher oxide and hydrogen levels.

760 °C
740 °C
740 °C
Melting
720 °C 730 °C

Melt cleaning 720 °C

Impeller 700 °C
690 °C
Transport
Holding furnace
Dosing 680 °C

650 °C
Metal in the
HPDC chamber

Fig 9: Typical temperature losses in melt handling during casting process; here with Castaduct-42, AlMg4Fe2

33
Castaduct®  - 42 [ AlMg4Fe2 ] – Properties

The dosage of the melt can be done by conventional dosing The die-casting mold inserts of the mold have to be preheated to
furnace or ladle furnace. temperatures of preferably above 180 °C, measured on the die-
The Castaduct-42 casting alloy has a higher tendency to oxidize casting mold surface. With the steady casting process, a surface
due to its higher Mg content and forms somewhat thicker oxide temperature of about 200 to 240 °C should be set, e.g. also be
skins compared to AlSi casting alloys. able for realization of long flow paths within the die-casting mold
cavity.
The carryover of oxide skins into the shot sleeve can be mini-
mized if the dosing launder between dosing furnace and shot For vacuum-supported structural casts, the use of double-sealed
sleeve is made of a ceramic material and this is additionally casting plungers, so-called vacuum casting plungers, is recom-
heated. mended. These ensure that when opening the vacuum valves less
of secondary air is drawn through the melt by air gaps between
A covered and heated dosing launder gives best performances. the casting piston and the shot sleeve, which could take part of
An optimum is the gassing of the closed and heated dosing tube rapidly solidified melt surface, and laden with oxides, into the run-
with dry nitrogen or argon. ner or even in the die-casting mold cavity.

When using a ladle furnace, the dosing ladle must be ceramic If a water-based mold release agent is used, it is recommended
and ideally can be preheated directly above the melt pool surface that it should be applied with 30 % to 50 % more concentrated
at high temperature. The oxide flags forming inside the ladle than is usual with AlSi casting alloys.
during the dosing process must be removed in a suitable manner This serves to better demolding of Castaduct-42 from the die-
before the renewed dosing process e.g. pour or blow out. casting mold contour, because Castaduct-42 tend to jamming.
Mold release agents developed for the processing of AlMg alloys
The dosing into the heated shot sleeve must take place as turbu- improve the flowability, the sliding on ejection and the weldability
lent free as possible in order to avoid renewed oxide formations, of the die-cast.
combined with the increase in H2 contents, optimally. I.e. low drop
heights or not too steep dosing launder draft angles must be It is highly recommended to apply a release agent using a min-
taken into account. imum-quantity spray process, i.e. water or oil based Microspray
application. This will be avoid the use of large amounts of water,
To minimize pre-solidification of the melt within the shot sleeve, which would lead to a high temperature drop at the die-casting
it must be heated right through to temperatures of above 250 °C. mold surface from casting cycle to casting cycle.
Ideally, this is done by a temperature control with thermal oil or an Furthermore, the visual quality of the cast surface and the quality
electric heater. of the cast in general significantly improves and the wear and
tear of the die-casting mold inserts is positively influenced.
It is recommended to maintain a filling ratio in the casting
chamber of about 50 %. The lower the filling ratio, the greater the Due to the jamming tendency of Castaduct-42 during solidifica-
temperature drop of the melt in the shot sleeve and the greater tion in the die-casting mold cavity, based on the higher shrinkage
the proportion of pre-solidification. factor in conjunction with the faster heat dissipation, the solidified
After dosing, the settling time of the melt within the shot sleeve cast must be demolded quickly from the die-casting mold inserts.
should be kept as short as possible. Ideal are times less than The practice with Castaduct-42 shows that the shortening of
2  seconds. the cycle times, in particular the significant shortening of the
solidification time in the 3rd phase, leads to a better ejecting of
Experience with the processing of Castaduct-42 showed that it the casts out of the die-casting mold. Thus, in general, the jam-
is possible to go without the biscuit cooling in the front end of ming tendency of AlMg die-casting alloys can be counteracted in
the shot sleeve, which is designed often as a water jacket. The a simple manner.
cooling of the biscuit takes place sufficiently quickly via the cast- At the same time a possible deformation of the cast is counter-
ing piston cooling and the impact plate or the protrude anvil, both acted during demolding.
with integrated cooling, both located at the movable mold half. By shortening the total cycle time, the temperature at the die-
This promotes the minimization of pre-solidification within the casting mold contour is maintained at the desired high level.
shot sleeve which is important for best cast quality.

34
 Castaduct®  - 42 [ AlMg4Fe2 ]

HPDC start and die-casting cycle The Castaduct-42 was stored and kept warm in a conventional,
Due to the jamming tendency also the initial casts must be com- closed dosing furnace at 710 °C, later in the course of the trial
pletely poured on the die-casting machine. at 690 °C.
Casting at too low shot speed will not ensure the integrity of the
cast and a safely demold of the cast is not possible. The ejector The temperature level of the die-casting mold was raised to
pins may pierce through the unfinished cast. above 200 °C. As a result, the die-casting mold temperature was
It is recommended to pour the initial casts with at least 70 % of on average 50 °C higher than that with AlSi alloys.
the plunger speed selected for the series process. Furthermore, it Significant is the reduction of the solidification time until ejection
is necessary to avoid any termination of the started 2nd phase in in the context of the trial of originally 16 seconds to 10 seconds.
the course of the HPDC cycle. The biscuit cooling at the front end of the casting chamber was
switched off.
As part of testing the Castaduct-42 in existing AlSi die-casting
molds, the solidification times could be reduced down to the The plunger speed for the die-casting shot was set for a cavity
single-digit seconds range! filling time of 49 ms, which made possible by the higher die-
The total cycle times in the die-casting process could be reduced casting mold temperature.
by one- or two-digit seconds using the Castaduct-42 die-casting
alloy! For the startup of the HPDC trial the release agent to water ratio
was increased for a more rich mixture from 1:100 for AlSi alloys
Trimming process to 1:50 for AlMg alloys.
The Castaduct-42 casts can be cooled directly from the casting All Castaduct-42 casts were trimmed hand-hot without problems
heat in a water bath or in air. The type of cooling has no notice- with the standard trimming tool by use of the automatic sequence
able influence on the material properties of the finished cast. in the die-casting cell.

For ductile die-casting alloys it is recommended to use a cutting A total of about 175 shots were poured, of which 130 shots
blade designed with a sloping surface, so that the ingate section, continuously without any interruptions. Overall, the casting result
runners, burrs, overflows and venting channels are cut off with was classified as very good. The mold filling capacity is pleas-
less force. Flat-faced punching blades squeeze with greater ef- ingly good. The casts could be poured cleanly without signs of
fort from the ingate section, with the risk of break-outs may exist. cold flow, hot cracks or pulling marks. The die-casting mold itself
When using cutting blades that are sloped with an angle of showed no adhesions or soldering in the area of the hollow cavity,
approx. 3° to 5°, the required stroke for the deburring cut only which would have led to pulling marks.
increases minimally.
The measured mechanical properties for yield strength (Rp0.2),
The trials in the context of alloy development showed that after tensile strength (Rm) and elongation (E) from Castaduct-42
demolding the cast from the die-casting mold, the shrinkage structural in as-cast condition were better at yield strength and
of the solid is only slightly greater than with casts made of AlSi elongation when compared to alloy AlSi10MnMg plus annealing
casting alloys: The casts made with Castaduct-42 were punched treatment to the state O.
on a trimming tool without damage, even if designed for trimming
of AlSi casts. Rp0.2 (YTS) Rm (UTS) A (E)
[ MPa ] [ MPa ] [%]

Case Study Structural cast 120 – 137 241 – 268 7.5 – 17.6
average 129 250 11.4
The sample cast was a structural casting with 910  mm length,
510  mm width and 6.5 kg part weight, with Castaduct-42 alloy Mechanical properties of HPDC trials with Castaduct-42, AlMg4Fe2

in a die-casting cell designed for AlSi10MnMg applications. The

shot weight was about 11 kg. In critical cast areas with strongly turbulent filling, individual lower
The wall thickness was over the flow path length of 850  mm in values for the elongation at break were measured analogously to
the region of the ingate 3.5  mm and in the back wall 2.5  mm. the alloy AlSi10MnMg at annealing state O.

35
Profile of the alloys for the die-casters

Get the spirit of RHEINFELDEN

Silafont  ®- 38 [ AlSi9MnMgZn ]
• applicable to thinnest wall •a
 lloying elements enables •h
 igh fatigue properties
designs and complex designs highest strength and good •e
 xcellent weldability and
• air quenching after solutionizing crash properties machinability
reduce distortion of the casts •g
 ood corrosion resistance due to • s uitable for self-piercing
exact alloy limits

Treatment state YTS [  M Pa  ] UTS [  M Pa  ] E [  % ] Hardness [ HBW  ]
water-T6 230 – 280 300 – 350 6 –9 90 – 115
air-T6 180 – 210 250 – 280 8 – 11 80 – 110

Castasil ®- 37 [ AlSi9MnMoZr ]
• no heat treatment needed to • long-term stability •h
 igh fatigue stress resistance;
reach high elongation • high yield strength and excellent highest compaired to AlSi-alloys
• good die-cast ejectability elongation in the as-cast state •e
 xcellent weldability
• usable even for thinnest wall due to defined alloying elements • s uitable for self-piercing riveting
thicknesses • very good corrosion resistance

Treatment state Wall thickness [  mm  ] YTS [  M Pa  ] UTS [  M Pa  ] E [  % ]
F 2–3 120 – 150 260 – 300 10 – 14
F 3–5 100 – 130 230 – 280 10 – 14

Castasil ®- 21 [ AlSi9SrE ]
• highest thermal and electri- • thin wall design possible • high yield strength and elongation
cal conductivity compared to • good die-cast ejectability in the as-cast state or after temper O,
AlSi die-casting alloys due to • long-term stability after compared to Al for rotors
low disturbing impurities temper O • suitable to flanging, clinching or
self-piercing, especially in temper O

Treatment state YTS [  M Pa  ] UTS [  M Pa  ] E [  % ] Conductivity [ IACS %  ]
F 85 – 100 200 – 230 6 –  9 < 43.5
O 80 – 100 170 –200 9 – 15 < 48.5

36
Magsimal ®- 59 [ AlMg5Si2Mn ]
• usage in the as-cast state for HPDC with •h
 igher shrinkage in comparison to AlSi-alloys
2 to 8  mm wall thickness •e
 xcellent corrosion resistance
• low melt oxidation due to patented alloy addition • v ery high fatigue strength
• high-tech alloy •e
 xcellent weldability, suitable for flanging,
• low sticking to the mold clinching and self-piercing riveting

Treatment state Wall thickness [  mm  ] YTS [  M Pa  ] UTS [  M Pa  ] E [  % ]
F 2–4 160 – 220 310 – 340 11 – 22
F 4–6 140 – 170 250 – 320 9 – 14

Magsimal ®- plus [ AlMg6Si2MnZr ]

• best in class YTS and still 8 % E in as-cast state • low sticking to the mold
for HPDC with 2 to 6  mm wall thickness •h
 igher shrinkage in comparison to AlSi-alloys
• low melt oxidation due to patented alloy addition •e
 xcellent corrosion resistance
• high-tech alloy  xcellent weldability, suitable for flanging, clinching
•e
• different alloying elements to control and self-piercing riveting

Treatment state Wall thickness [  mm  ] YTS [  M Pa  ] UTS [  M Pa  ] E [  % ]
F 2 –3 200 – 220 340 – 360 9 – 12
T5 2 –3 230 – 250 350 – 380 8 – 12

Castaduct ®- 42 [ AlMg4Fe2 ]
• usage in the as-cast state especially for large •n
 o sticking to the mold due to high Fe content
and thin wall HPDC • higher shrinkage due Si is < 0.20 %
• low melt oxidation due to special alloy addition • highest elongation even at room temperature
• smart alloy composition with an AlFe eutectic • excellent corrosion resistance
• easy handling • long therm stability

Treatment state Wall thickness [  mm  ] YTS [  M Pa  ] UTS [  M Pa  ] E [  % ]
F 2–4 120 – 150 240 – 280 10 – 22

37
Technical informations

This chapter is provided on how to work with our casting alloys in the melt process and how to gain optimum pouring
results. In the various steps in the die-cast process as possible grain refinement, strontium modification, quality of
melt, heat treatment for HPDC, surface coating, and joining techniques for the HPDC is hereby received.

We consider this a very important part of the manual as it isn’t just the quality of casting alloy used which is key
to successful applications, the right way of working before, during and after pouring is also of great importance.
More questions will certainly arise during your work and as new developments enter the market.
The RHEINFELDEN ALLOYS foundry specialists will happily answer these.

The mechanical properties are based on in-house measurements of our alloys and if applicable most exceed the
values stipulated in the EN 1706 European standard.

The mechanical values were measured at tensile bars, machined from HPDC. The ranges of mechanical properties
stated indicate the performance of the alloys and the amount of scatter depending on material and pouring. The re-
spective maximum value is for the designer’s information. These values can also be reached in the cast or sub-areas
with favorable casting conditions and corresponding casting technology work.

The HPDC alloys supplied by RHEINFELDEN ALLOYS have small and precisely defined analysis ranges in order to
ensure good uniformity in the casting process and other properties.

Processing datasheets
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alloy f­ amily can be used. The recommendations correspond to typical foundry circumstances.
ol
in
g

For example a crucible or tower melting furnace is considered for melting down;
the circumstances in a huge melting furnace may differ from the recommendations. Fine returns should also
not be used for primary aluminum HPDC alloys.

The volumes listed here are all percentages by weight, calculated for the charge weight. The temperatures quoted all
relate to the temperature of melt, even for casting. The heat treatment recommendations apply for the standard process
and may be varied, to minimise distortion for example.

If you have any questions relating to your specific alloy application and processing, please contact our foundry experts.

38
 Silafont ®- 38 [ AlSi9MnMgZn ]
Sequence of work when producing high pressure die-casts from Silafont-38

1 Melting down the ingots As quickly as possible in efficient furnaces to keep magnesium melting loss, gas
absorption and oxidation of melts low; replenish preheated ingots and returns
in small volumes to avoid segregation and entrapped oxides; proportion of returns
may extend to 50 %

2 Flux treatment Not needed when melting

3 Magnesium burnout Normally a melting loss of 0.03 % per fusion; compensation is only required if the
magnesium content of the melts is outside tolerance, add magnesium master alloy
or pure magnesium

4 Strontium burnout Usually melting loss of 30 – 50  ppm per fusion; Sr should only be added if the Sr
­content of the melts is less than 80  ppm, add AlSr5 or AlSr10.
When fusing for the first time in a new crucible or in a crucible which has not yet
been used for Sr-­modified alloys, the Sr content falls sharply. Strontium will diffuse
into the crucible, saturation is reached after the first fusion

5 Skimming Needed after melting down

6 Temperature After melting down maximum of 780  °C for holding temperature

7 Degassing and refining the melts • In the transport crucible, better in a holding crucible or receptacle or in a dosing
furnace with bottom blocks; effective refining and fastest method using
quick-­running rotor for gas feeding, 7 – 10 l/min argon or nitrogen, 6 – 10 min
• Gas flushing lance with fine porous head, needs longer treatment times (  cooling !  )
•G
 as flushing tablets emitting nitrogen in the bell plunger procedure are not very
suitable

8 Skimming Required after melting down; the metal content of the skimmings may be reduced
by adding melt fluxes within or after the impeller treatment

9 Pouring temperature (approx. values) 680 – 710  °C – depends on design, flow path and wall thickness of high pressure
die-cast, but also on the length of the flow channel in the dosing furnace and pos-
sibly on chamber heating

10 Mold temperature Mold surface temperature 250 – 350 °C

11 Solution heat treatment 470 – 490  °C / 2 – 3 hours; for special components: 420  °C / 0.5 hours

12 Cooling with air Immediate air cooling with a cooling rate of > 3 °C / s is only achieved with an inten-
sive air stream (down to 200 °C) and results in lower distortion. If cooling in the air,
only a significantly lower yield tensile strength can be obtained

13 Cooling with water In water ( 10 – 60  °C ) without a delay wherever possible

14 Delay time before artificial ageing Only if straightening is needed, usually maximum of 12 hours

15 Full artificial ageing T6-water 155 – 190  °C / 1 – 3 hours

16 Full artificial ageing T6-air 155 – 210  °C / 1 – 3 hours

The annealing and ageing times stated apply without a heating-up time

39
 Castasil ®- 37 [ AlSi9MnMoZr ]
Sequence of work when producing high pressure die-casts from Castasil-37

1 Refining Clean furnace, crucible, treatment and casting tools to avoid impurities from
unwanted elements such as Cu, Zn and especially Mg !

2 Melting down the ingots The melt should be quickly heated to above 670  °C to avoid segregations, e. g. of the
solid solution containing Mn in the melt. The temperature of melt should not exceed
780  °C. An Sr melting loss should be expected when melting and keeping warm –
the higher the temperature, the greater the loss. Sr melting loss should be expected
in particular when melting down returns and degassing treatment is recommended to
remove the H2 and oxides. As the Sr content increases, so does the tendency for the
melt to absorb hydrogen; this should not therefore exceed 350  ppm.

3 Flux treatment Not needed when melting

4 Strontium burnout Usually melting loss of 30 – 50  ppm per fusion; Sr should only be added if the Sr
content of the melts is less than 60  ppm, add AlSr5 or AlSr10.
When fusing for the first time in a new crucible or in a crucible which has not yet
been used for Sr-modified alloys, the Sr content falls sharply. Strontium will diffuse
into the crucible; saturation is reached after the first fusion

5 Skimming Needed after melting down; as well as their potential for danger, cold tools may
result in molybdenum segregation

6 Temperature after melting down After melting down maximum of 780  °C for holding temperature. Don’t keep the melt
at temperature below 680 °C and steer melt if possible

7 Degassing and refining the melts • In the transport crucible, better in casting or dosing furnace; effective refining and
fastest method using quick-running rotor for gas feeding, 7 – 10 l/min argon or ni-
trogen, 6 – 10 min; during degassing in the transport crucible, cooling of 30 – 50  °C
should be expected
• Gas flushing lance with fine porous head, needs longer treatment times ( cooling ! )
• Tablets for melt cleaning are inefficient

8 Skimming Required after degassing; the metal content of the skimmings may be reduced by
adding melt fluxes during or after impeller treatment

9 Pouring temperature (approx. values) 680 – 720  °C depends on design, flow path and wall thickness of high pressure
die-cast, but also on the length and insulation of the flow channel from the dosing
furnace and on use of shot sleeve heating.
Temperature losses may cause initial solidification and should therefore be avoided

10 Mold temperature 250 – 350  °C, depending on cast and requirements of mechanical properties
As a rule: the warmer the mold, the higher the elongation and the lower the strength.

11 Casting chamber temperature Preheat the chamber electrical or with oil > 200 °C

40
 Castasil ®- 21 [ AlSi9SrE ]
Sequence of work when producing high pressure die-casts from Castasil-21

1 Refining Clean furnace, crucible, treatment and casting tools to avoid impurities from
unwanted elements such as Cu, Mg, V, Cr and especially Mn an Ti!

2 Melting down the ingots The melt should be quickly heated to above 670  °C to avoid segregations, e. g. of the
solid solution containing Mn in the melt. The temperature of melt should not exceed
780  °C. An Sr melting loss should be expected when melting and keeping warm –
the higher the temperature, the greater the loss. Sr melting loss should be expected
in particular when melting down returns and degassing treatment is recommended to
remove the H2 and oxides. As the Sr content increases, so does the tendency for the
melt to absorb hydrogen; this should not therefore exceed 350  ppm.

3 Flux treatment Not needed when melting

4 Strontium burnout Usually melting loss of 30 – 50  ppm per fusion; Sr should only be added if the Sr
content of the melts is less than 100  ppm, add AlSr5 or AlSr10.
When fusing for the first time in a new crucible or in a crucible which has not yet
been used for Sr-modified alloys, the Sr content falls sharply. Strontium will diffuse
into the crucible; saturation is reached after the first fusion

5 Skimming Needed after melting down

6 Temperature after melting down After melting down maximum of 780  °C for holding temperature. Don’t keep the melt
at temperature below 680 °C and steer melt if possible

7 Degassing and refining the melts • In the transport crucible, better in casting or dosing furnace; effective refining
and fastest method using quick-running rotor for gas feeding, 7 – 10 l/min argon
or nitrogen, 6 – 10 min; during degassing in the transport crucible, cooling of
30 – 50  °C should be expected
• Gas flushing lance with fine porous head, needs longer treatment times ( cooling ! )
• Tablets for melt cleaning are less efficient

8 Skimming Required after degassing; the metal content of the skimmings may be reduced by
adding melt fluxes during or after impeller treatment

9 Pouring temperature (approx. values) 680 – 720  °C depends on design, flow path and wall thickness of high pressure
die-cast, but also on the length and insulation of the flow channel from the dosing
furnace and on use of shot sleeve heating.
Temperature losses may cause initial solidification and should therefore be avoided

10 Mold and chamber temperature 250 – 350  °C, depending on cast and requirements of mechanical properties
As a rule: the warmer the mold, the thinner the fins may be designed.
Preheat the chamber electrical or with oil > 200 °C

11 Annealing to high conductivity 250 – 350  °C for 2 – 3 hours; for special purpose 440 °C for 6 hours
in temper O
The annealing and ageing times stated apply without a heating-up time

41
 Magsimal ®- 59 [ AlMg5Si2Mn ]
Sequence of work when producing high pressure die-casts from Magsimal-59

1 Melting down the ingots As quickly as possible in efficient furnaces to keep Mg melting loss, gas absorption
and oxidation of melts low; replenish preheated ingots and returns in small volumes to
avoid segregation; use refractory materials with a high clay content; avoid phospho-
rous and sodium absorption

2 Flux treatment Prohibited to use usual flux ! There is a risk of sodium (Na) pick up

3 Magnesium burnout Normally melting loss of 0.1  % per fusion, correction not normally needed; if the Mg
content is significantly below 5.0 %, add pure magnesium of maximum 0.5 %

4 Skimming Needed after melting down

5 Temperature after melting down Maximum of 780  °C ( check temperature ! )

6 Temperature in holding furnace Holding furnance temerature: 700 – 720 °C

Do not allow to fall below 650  °C and keep melt moving by means of:
• convection
• rotor ( impeller )
• use bottom injection of N2
• melt pouring
Do not use deep furnace with cover heating if melt is calm !

7 Degassing and refining the melts • Effective refining and fastest method using quick-running rotor for gas feeding,
7 – 10 l/min argon or nitrogen, 6 – 10 min
• Gas flushing lance with fine porous head, needs longer treatment times ( cooling ! )
• Gas flushing tablets do not achieve the necessary effect !

8 Skimming Careful skimming needed!

Only totally Na-free fluxes may be used to reduce the metal content of skimmings!

9 Grain refining Prohibited !

10 Modification Prohibited ! The elongation achievable would be reduced considerably

11 Pouring temperature (approx. values) 690 – 730  °C, varies depending on design, size and wall thickness of high pressure
die-casts

12 Mold temperature and Mold surface temperature 250 °C to 350  °C, depending on cast and requirements of
casting chamber temperature mechanical properties
As a rule: the warmer the mold, the higher the elongation and the lower the strength.
Preheat the chamber electrical or with oil > 200 °C

13 Quenching casts after removal Immediate quenching in water reduces the yield tensile strength and
from mold increases elongation

14 Heat treatment Normally none

15 stress-relief annealing Only in special cases for T5 and O; if necessary, age T5 at up to 250  °C and
for up to 90 min, the yield tensile strength will increase and elongation decrease;
if necessary, age O at between 320  °C and 380  °C and for up to 90  min,
the yield tensile strength will decrease and elongation increase

42
 Magsimal ®- plus [ AlMg6Si2MnZr ]
Sequence of work when producing high pressure die-casts from Magsimal-plus

1 Melting down the ingots As quickly as possible in efficient furnaces to keep Mg melting loss, gas absorption
and oxidation of melts low; replenish preheated ingots and returns in small volumes to
avoid segregation

2 Flux treatment Prohibited to use usual flux! There is a risk of sodium (Na) pick up

3 Magnesium burnout Normally melting loss of 0.1–0.2 % per fusion, correction not normally needed; if the
Mg content is significantly below 6.0 %, add pure magnesium of maximum 0.5 %

4 Skimming Needed after melting down

5 Temperature after melting down Maximum of 780 °C (check temperature!)

Holding furnance temerature: 700 – 720 °C

6 Temperature in holding furnace Do not allow to fall below 650 °C and keep melt moving by means of:
• convection
• rotor (impeller)
• use bottom injection of Nitrogen-gas (N2)
• melt pouring
Do not use deep furnace with cover heating, if melt stays calm!

7 Degassing and refining the melts • Effective refining and fastest method using quick-running rotor for gas feeding,
7 – 10 l/min argon or nitrogen, 6 – 10 min
• Gas flushing lance with fine porous head, needs longer treatment times (cooling!)
• Gas flushing tablets do not achieve the necessary effect!

8 Skimming Careful skimming needed!

Only totally Na-free fluxes may be used to reduce the metal content

9 Grain refining Prohibited!

10 Modification with Na or Sr Prohibited! The elongation achievable would be reduced considerably

11 Pouring temperature (approx. values) 690 – 730 °C, varies depending on design, size and wall thickness of HPDC
Mold surface temperature 250 °C to 350 °C, depending on cast design and require-
ments of mechanical properties

12 Mold temperature and As a rule: the warmer the mold, the higher the elongation and the lower the strength.
casting chamber temperature Preheat the chamber electrical or with oil > 200 °C

13 Quenching casts after removal Immediate quenching in water reduces the yield tensile strength and increases elon-
from mold gation. Stabile mechanical propeties are achieved after 20 days

14 Heat treatment with solutionising Normally none

15 Rapid annealing with T5 If necessary, age T5 at 170 °C up to 250 °C and for 30 up to 90 min, the yield tensile
strength will increase and elongation decrease slightly

16 Stress-relief annealing like temper O If necessary, age at temperature between 320 – 380 °C and for up to 90 min, the yield
tensile strength will decrease and elongation increase

43
 Castaduct ®- 42 [ AlMg4Fe2 ]
Sequence of work when producing high pressure die-casts from Castaduct - 42

1 Melting down the ingots As quickly as possible in efficient furnaces to keep Mg melting loss, gas absorption
and oxidation of melts low; replenish preheated ingots and returns in small volumes to
avoid segregation.

2 Flux treatment during melting down Not needed when melting ingots; useful for avoiding oxidation when using small
returns. Prohibited to use usual flux! There is a risk of sodium (Na) pickup.

3 Silicon limit and pickup Si is an impurity and should be below 0.2 % in the cast. Don’t melt after AlSi alloys.

4 Magnesium burnout Normally melting loss of 0.1– 0.2 % per fusion, correction normally not needed; if the
Mg content is significantly below 4.0 %, add pure magnesium in portion of 0.4 %.

5 Iron content Normally no correction of Fe is needed

6 Skimming Needed after melting down

7 Temperature after melting down Maximum of 760 °C (check temperature!)

8 Degassing and refining the melts • Effective refining and fastest method using quick-running rotor for gas feeding,
7 – 10 l/min argon or nitrogen, 6 – 10 min
• Gas flushing lance with fine porous head, needs longer treatment times (cooling!)
• Gas flushing tablets do not achieve the necessary effect!

9 Skimming Careful skimming needed!

Only special Na-free fluxes may be used to reduce the metal content of skimmings!

10 Temperature in holding furnace Do not allow to fall below 660 °C and keep melt moving by means of:
• convection
• rotor (impeller)
• use bottom injection of N2
• melt pouring
Do not use deep furnace with cover heating if melt stays calm!

11 Grain refining Not needed for thin-walled die-casts

12 Modification of Si Silicon content is below 0.15 % in the Castaduct-42. Modifying elements like Sr and P
are without any influence. Na content > 10  ppm should be avoided.

13 Pouring temperature 680 – 710 °C, varies depending on design, size and wall thickness of high pressure
(approx. values) die-casts

14 Mold temperature and Mold surface temperature: between 200 and 350 °C
casting chamber temperature (depending on design, size and wall thickness of cast)
Preheat the chamber electrical or with oil > 200 °C

15 Quenching casts after removal No variation in mechanical properties either with rapid water cooling nor with cooling
from mold with air

16 Heat treatment Normally none

Up to 350 °C no influence to the metallic structure!

44
 Technical information

Design of structural die-casts

Die-casted structural components are typically large stability-
giving components, in which high component reliability is required
D D
and which should withstand high deformations in the event of
crash of vehicles. This structural casts has to meet demands for C
high strength and elongation with fewest errors as possible in the
cast structure. A structural cast is connected in individual areas
A
with other components by welding, gluing, riveting or crimping.

The material-side fulfillment of high strength requirements, as

possible without heat treatment to be applied, improves the
dimensional accuracy of structural casts. The additional demand B
for lightweight construction is also met by thin-walled design and
high functional integration. Fig. 1: A
 n example of good fin design

A: Thin fin with lowered height in the middle of the length,

also to reduce thickness at the fin ground
Important for the production of structural casts is a castable
B: Adjusted core depth in small core areas
component design with reliable processing technology of the
C: Ejector pin location in a tilted wall
HPDC alloys presented in this manual. Some hints for the design
D: Additional core pins in the area of narrow high fins
of the casts as well as the die-casting molds are given here. We
recommend that you follow these design suggestions, especially
when using our Magsimal-59 / -plus and Castaduct-42 alloys.

On the machine side, thin-walled structural casts with wall thick-

nesses of around 2.0  mm can be realized with flow path length
of approximately 1.0  m. However, it is important to ensure that
C
the wall thickness from casting ingate section to the end of mold B
filling is performed from thick to thin, so for example from 3.5  mm B
to 2.0  mm.
B
In the case of the more strong shrinking AlMg casting alloys, the
A
draft angles should be performed on contours and cores prefer-
ably minimum 1.5 °. Cast contours that tend to shrink more strong,
as well as deep, slender fin contours must be supported with
C
sufficient amount of ejectors for demolding from the die-casting
mold. Examples are expressed in Fig. 1.

The diameter of the ejector pins should not be less than 6.0  mm, Fig.  2 : An example of good fin design

since AlMg casting alloys are expected to have significantly high- A: Fin node reducing massive concentration

er demolding forces compared to AlSi casting alloys. Also, the B: High incoming forces are spreaded by several fins

risk of buckling of the ejector pins can be avoided in a practicable C: Thicker diameter of ejector pins to reduce pressure force

way. In practice, the demolding forces are about one-third higher

and may be even higher depending on the cast design. Additional
ejector pins also significantly reduce the surface pressure on the
hot cast and with this the possible distortion of the cast.

45
Technical information

The demolding of long cores should preferably be done via sleeve

ejectors. Where this cannot be done, hydraulically operated un-
derfloor core pullers can be a viable solution.
C
When designing fins in a cast, nodes with undesirable accumu-
lations of material should be avoided wherever possible.
In particular, high fins with large amount of taper at the flanks
cause significant volume in the bottom of the fins. The volume
A B
contraction in such accumulations of material then causes
externally visible sink marks at the floor bottom. Remedy can
be here design provided beadings on the floor bottom side. Fig.  3 : An example of good fin design

A: Design of an U-profile with thin fins, lowered in height tofollow the real stress
curve in case of load (FEM calculations)
Deformations or even demolitions of large, core-shrinking
B: Separated conjunction of fins to the outer wall to avoid thicker areas
accumulations of material, such as assembly domes in the re-
C: Hollow design on the back-side of assembly domes
gions of thin-walled cast contours, must be avoided. Important
for such assembly domes is a generous connection to the
thin-walled cast contours with the help of larger fin structures
(Fig. 3).

Advantageous for large-area fin designs with good component

rigidity and improved NVH characteristics are honeycomb-like fin
structures. As a result, unfavorably designed and narrow tapered
die-casting mold contours are avoided for the steel mold in a
simple manner. The honeycomb structure with its hexagon design
typically leads to 120 ° angles in the steel mold and thus reduces
hot spots with the risk of hot work steel tempering temperatures
above 550 °C during cavity filling (Fig. 4).
Fig. 4: A
 n example of good fin design:
Honeycomb structure reduce hot spots on the mold steel
Small radii or even sharp edges should be avoided in die-cast
design, especially when using AlMg casting alloys. Design
specifications similar to Mg die-cast should be used. Small radii
lead to hot cracks during solidification of the metal in the die-
casting mold cavity, if there are long, freely shrinking solidification
paths is present next to it.

Heat sinks and hot cracks in the area of inner radii can be
defused by small additional fins. The skin layer formation is then
improved by the larger contact surface with the hot-working
steel (Fig. 5–7).

Other good examples of casting-oriented design are the BDG/

VDG guideline K200 as well as the BDG/VDG guideline for die-
cast made of non-ferrous metals.

Fig. 5: S olidification support through riffles; an example of solving inner edge

problems through small marks

46
 Technical information

Design of the die-casting mold

For the production of large and thin-walled structural die-casts,
not only the casting alloy used, but also the die-casting mold
itself has to be designed to reproduce long flow paths.
C

Ideal for thin-walled die-casts with Castaduct-42, Magsimal-59

or Magsimal-plus is the close-to-contour design of the cool-
ing and tempering inside the mold inserts. For the die-casting
process, a temperature control of the mold inserts to over 200 °C
is recommended.
B
An adjustment of the thermal balance of the die-casting mold by
spraying the die-casting mold contour with the help of water
A
in combination with release agents should be avoided as far
as possible. This is because stress cracks on the steel occur
early when the temperature difference is particularly high. Fig. 6: HPDC design to ensure forced solidification in the cast

It is recommended to carry out the release agent application A: Thinnered wall with small waffle pattern design to enlarge contact area

using a minimum-quantity spraying process. In this case, water, B: Separated fin connections

powder or oil-based release agents can be used. Modern C: Outer contour casted with core to cast a wall with uniform thickness

simulation programs are of great help in the design of the

thermal balance of a die-casting mold.

An intensive cooling of the mold inserts in the area of the cast

runner allows rapid removal of the cast from the die-casting
mold. Although a flat and wide developed cast runner increases
the pressure surface within the die-casting mold and thus the
necessary locking force, but it leads to significantly reduced so-
lidification times. Thus, the casts can be demold in a faster way. C

Furthermore, large, flat cast runners can be divided more easily

with less effort during the deburring cut. An advantage when
it comes to the handling of return scraps. A

The runner as well as the ingate section has to be designed for

low turbulence and fluid flow favorable run, so without small radii B

and without sharp-edged transitions. Because these increase

the flow resistance significantly and it is a greater casting force Fig. 7: Good HPDC design to ensure forced solidification in the cast

needed for the cavity filling. Cavitation effects lead to local A: Thin wall with narrow small waffle pattern design to enlarge intensively
the contact surface
vacuum zones with cross-sectional constrictions in flow-cross
B: Assembly domes with hollow casted center
sections and can suck in air via the die-casting mold parting lines
C: Solving inner edge problems through small marks
and with this into the melt.

The runner ingate section has to be placed into areas of the cast,
where the incoming melt do not immediately encounters a trans-
verse and rise barrier inside of the cavity within the flow direction.
This leads, regardless of the casting alloy used, to very strong
friction of the melt on the die-casting mold contour, so very
quickly to local heat up, and as a result, to sticking and strong
erosion. Even a significant loss of flow energy is expected.

47
Technical information

The ingate cross-section has to be generously dimensioned so The die-casting mold inserts in the mold frame must be rigidly
that the ingate speed of the melt remains between about 30 to supported so that elastic movements are avoided in the best
60 m/s and nevertheless a short cavity filling time is achieved. A way possible during the HPDC process. If this is not taken
short cavity filling time is necessary to reduce casting defects in into account, the movement of a mold insert can increase the
thin-walled structural die-casts. jamming effect of the solidifying casting alloy and significantly
For the significant improvement of the flow properties in a die- hinder demolding from the mold. With unfavorable die-casting
casting mold cavity with Castaduct-42 or Magsimal-59 / Mag- mold construction this can lead to the jamming of the cast on the
simal-plus alloys a slightly roughened surface structure on the sprue side of the mold, where no ejector pins for demolding are
die-casting mold contour is suitable. For this purpose, the local available.
application of tungsten carbide layers as well as for large-scale
application eroded, blasted or etched surfaces are suitable.

Also, waffle patterns are useful for improving flow properties in

thin walled areas of casts, whereby the wall thickness between
the small fins may decrease down to 1.2  mm (Fig. 6 and 7).

The die-casting mold for structural casts must be designed for a

vacuum-assisted casting process. In this case, the correctly sized
venting cross section is of great importance. It determines the
achievable flow path length of the liquid metal within the cavity
and the residual porosity in the cast (Fig. 8).

An as closed as possible melt front with only few dividing and re-
joining melt front areas leads to less oxide formation during cavity
filling and thus experience shows to significantly better casting
results, than a chaotic and highly turbulent filled cavity. Converg-
ing and thus oxide-affected melt fronts must be able to run into
overflows and ventilation channels in a defined manner.
Fig. 8: Image of a simulation to reduce entrapped air in the mold due better venting

Far-off ingate lying material accumulations, which cannot be feed

via the thin-walled structures of the cast during solidification,
must preferably be rapidly cooled. This can also be realized with
highly dissipating die-casting mold contours made of wear-
resistant tungsten steel parts inserts. Also specially designed
core pins with internal cooling channels lead to a good heat
dissipation.

Parts of die-casting mold inserts with almost any designed inte-

rior cooling can also be produced using the 3D forming process
SLM. Here, however, the recommendation is to dimension the
cooling channel cross-sections sufficiently large so that they do
not block in the casting operation by deposits.

Nevertheless, upcoming shrinkage deficits in the area of material

accumulations, which are far-off the ingate section, can be feed
by using hydraulically actuated squeezers which are common in
practice.

48
 Technical information

Eight Target levels for HPDC

Fig. 9 shows eight levels of the HPDC process, which finally are necessary result in a cast suitable
for welding and heat treatment.

It may be more comfortable to choose an proper alloy then to handle the different HPDC processes.
Therefor also some HPDC alloys described in formers handbooks are named here.

There are higher requirements for the process of structural casts than for general purposes.
Depending on your requested targets shows the eight-level-staircase for the main areas of HPDC
some suggestions. We divide between dosing technique, air reduction in the cavity, melt handling
and application of mold release agent.

A requested high cast quality requires on the one hand the use of high-quality die-cast aluminum
alloys, also with a metallurgically proper handling of the returns. On the other hand is the consistent
application necessary by die-cast fundamentals for technical cast design, such as ingate design.

Solution
heat
Can be subject treatment
to high dynamic Welding
r HPDC
Targe t levels fo Glueing, loads
High yield riveting
tensile Flanging
Light and strength
thin

Mold release
Dimension Micro spray application

agent
Minimisation of mold release agent
Modern mold release agent

Controlled transport of melt

Melt
1st phase with less turbulence
Refining treatment of melt

HPDC method and stages needed Vacuum application

Active enforced venting, vacuum supported

Air
Passive enforced venting / Chill vents
Effective use of overflows (simulation)

Vacuum supported
technique
Dosing

Closed holding furnace

Crucible, electrical heated
Isolation of liner and ladle
Castaduct-42 Magsimal-plus AlSi10Mg ( Fe ) Silafont-09 Silafont-09 Silafont-36 Silafont-36 Silafont-36 T6
AlSi9Cu3 ( Fe ) Castaduct-42 Silafont-36 with Silafont-36 with Silafont-36 T7 Silafont-38 Silafont-38 Silafont-36 T7
and others AlSi12 ( Fe ) T5 Mg > 0.3 % Mg < 0.20 % Castasil-37 Castasil-37 Castasil-37 Silafont-38 T6
and others Silafont-38 T5 Castasil-37 Magsimal-59 Magsimal-59 Castasil-21
Magsimal-59 Magsimal-59 Castaduct-42 Magsimal-plus Magsimal-59
Magsimal-plus Castaduct-42 Castaduct-42 Magsimal-plus
Castaduct-42

Suitable high pressure die-casting alloys

Fig. 9: Eight target levels of high pressure die-cast with details of the alloys to use and the HPDC method and stages required

49
Technical information

Surface coating techniques for die-casts skins are included in the cast during the mold filling, which may
Maximum surface condition requirements are defined for pres- cause blister formation during baking of the coating.
sure die-casts which are to be coated or anodized. This applies
specifically to top-quality coatings which must meet maximum Influence from the HPDC process
requirements, with regard to decorative appearance and resistance Mold release agents, preferably water based, are used for smooth
to corrosion for example in the automotive or aviation industry. and easy removal of casts from the mold. Some of these burn into
the cast skin. Release agents containing silicon or graphite can
The following parameters have considerable influence on thus cause considerable problems. The gate area is in some cases
flawless coating or anodizing: additionally greased in order to prevent soldering to the mold due
• Pressure die-cast design and process to increased thermal load. The ingate should not be in the visible
• Mold design and metal flow area of the cast as far as possible. These lubricants also cause
• Handling and machining adhesion losses for coatings. Therefore a very economical use of
these lubricants is recommended for casts to be coated.
Here some design and processing tips are reported to help
preventing detrimental influences on the coating/anodizing. Surface pre-treatment
The mechanical effect of frequently applied vibratory grinding
Influence from the cast design processes is often insufficient to reliably remove cast skins,
The cast design should have no sharp edges and small radii so that a shot blasting process is recommended.
below 2  mm. “Thinning-out” causes running away of the
coating film at the edges during baking with significantly lower Heat treatments at solutionizing temperatures above 450 °C,
coating thicknesses (Fig. 10). such as T4, T6 and T7 for AlSi10MnMg, produce highly oxidized
surfaces which must be considered during surface pre-treatment.
Undercuts and bores always present problem areas in the
frequently applied electrostatic coating technology, which can Ceramic media, such as corundum in particular, are very suitable
only be covered evenly with electro-dip painting (KTL). shot blasting media. Glass beads or aluminum granules cause
only slight material removal. Not suitable are metals and plastics,
Influence from the mold design which cause painting adhesion losses due to the penetration of
At least 1 % draft angle for the AlSi-alloys and at least 1.5 % for flakes into the workpiece surface. Residual iron particles also
the AlMg-based alloys should be assumed. Hot cracks may form nuclei for pitting corrosion.
appear in thermally loaded areas of the cast with older molds. When using coolants for machining, it must be taken into account
These mold crack marks and other burrs must be removed as that they have to be completely removed immediately afterwards
they cause “paint thinning” on their sharp edges. Deep mold cavi- by degreasing. Coolants attacking aluminum must not be used.
ties without melt flow through possibility must be designed with Material compatibility and removableness of coolants must deter-
overflows so that no air, release agent residues or any oxide mine their selection (Fig. 11).

Fig. 10: T
 wo-part cast for rear swinging fork for motorbike; multi-path welded Fig. 11: Flow meter for jet fuel; chromated before coated
structure in stiff design; powder coated

50
 Technical information

It is necessary to clean chemically the work piece prior to shot Joining techniques for die-casts
blasting as residues from lubricant or crack testing agents can Adhesive bonding
be hammered into the workpiece surface by the shot blasting Magsimal-59, Magsimal-plus, Castasil-37 and Castaduct-42 are
process. die-casting alloys with the requested properties for structural
application in the as-cast state. There is no dimensional correction
Large quantities of the mold release agents and piston lubricants needed due to the missing heat treatment. That gives high
are particularly problematic as they cause burnt oil carbon residues benefit to assembling with adhesive bonding. Additionally there
on the cast. Keep this in mind especially for parts in the as-cast is no longtime influence through our alloys, due low Cu and Zn
state. content.

Alkaline pickling processes for targeted roughening of the sur- Flanging

face are not recommended for the surface treatment of AlSiMg- AlSi10MnMg with a magnesium content of approx. 0.16 % can
pressure die-casts. The high silicon content cause dark, insoluble be used particularly for flanging technology. The designer can
residues during alkaline pickling. Subsequent acid pickling is then thus join the aluminum pressure die-casts to other materials such
unavoidable for removing this “pickling deposit”. Our AlMg alloys as steel and plastic. This can be applied as fixing but also as
don’t show such effect. To optimize the paint adhesion with the structural joining technology with appropriate construction design
AlSi-alloys we suggest a chromate pre-treatment. (Fig. 12). The configuration of the flanging edge mostly requires
an elongation of at least 8 % on the pressure die-cast material.
Effect of baking temperatures Therefore high internal quality requirements are set on this area
Electrostatically adhering powder particles should be sintered of the cast. As consequence, in this kind of applications the de-
together on HPDC at target temperatures of 120 to maximum sign of the mold must guarantee good metal flow in the flanging
200 °C. A change occurs in the mechanical properties of edge, what has to be kept in mind especially with Magsimal-59
AlSi10MnMg during the coating process starting from 150 °C and Castaduct-42.
after 1 hour; with Magsimal-alloys this happens only above
180 °C. Furthermore mechanical properties of Magsimal-59
and Magsimal-plus gets stable after paint bake cycle treatment
with temperature above 180 °C.
Castasil-37, Castaduct-42 and Castasil-21 shows no changes.

Fig. 12: Vibration damper housing made of Fig.13a: C

 ross section of a self-piercing riveting trial, Fig. 13b: View from below
AlSi10MnMg, with structural flanging 5  mm rivet, 1.5  mm AlMg3 sheet metal, under
Castasil-37 die-cast plate in the as-cast state (F)

51
Technical information

Self-piercing riveting High pressure die-casts made from Silafont-36, Silafont-38 and
Joints in which the cast is the lower layer in the riveting joint, Castasil-37 are particularly well suited to welding, with both MIG
have particularly high requirements concerning the absence and TIG standard methods. The S - AlSi5 or S - AlSi10 welding
of defects in the casting material. Figures 13a and 13b show the addition material is preferred for welded designs with AlMgSi0.5
result of a self-piercing riveting trial in our laboratory. wrought alloys.

It should be noted that Castasil-37 can be self-piercing riveted The AlMg-based alloys, like Magsimal-59, Magsimal-plus and
in the as-cast state also under these severe design conditions, Castaduct-42 have a higher shrinkage rate and force than AlSi
i.e. using a rivet mold with flat geometry. The Castasil-37 batch HPDC alloys. Mold release agents recently developed for work
used for this trial had a yield strenght of 114 MPa, an ultimate with alloy family improve both the ease of flow, i.e. ability to slide
tensile strength of 255 MPa and 14 % elongation. A further during ejection, and therefore the suitability of the high pressure
improvement in deformability is achieved in temper O. die-casts for welding.

Ask for our experience in self-piercing riveting with our other Design welding with casts made from Magsimal-59, Magsimal-plus
alloys for structural design demands. and Castaduct-42 are undertaken with the addition material
S - AlMg4.5Mn using the TIG method. Unlike the case with elon-
Welding gation, the mechanical properties in the heat influence zone
All here mentioned HPDC alloys are suitable for friction stir are hardly affected. The use of S-AlSi5 in AlMg die-cast alloys
welding and other pressure welding methods. would result in a decrease in elongation, and also to cracking in
the weld.
The suitability of HPDC for fusion welding is highly dependent
on the processes. There is no tendency for hot tearing with these Wall thickness YTS UTS E
die-cast alloys. Alloys, melting and die-casting methods which 4  mm [MPa] [MPa] [ %]

ensure low gas absorption and oxide impurity during HPDC are Ma-59 not welded 165 287 17
Ma-59 welded 148 246 6
needed.

The designer may place weld seams in zones with less loading, All die-casting alloys are well suited for friction stir welding or
but preferable they should also be close to the ingate, due cast spot welding. Spot and laser beam welding processes must take
quality generally is there higher. the special features of aluminum material into account.

Patented by RHEINFELDEN ALLOYS are the alloys Magsimal-59, Magsimal-plus, Castasil-37 and Castasil-21. Silafont-38 and
Castaduct-42 are in status patent pending.

We would like to thank all our business partners who have provided have provided casts or photographs for this publication.
Special thanks to AUDI AG for the ASF picture on the front side and RWP Simtec for a picture about casting simulation.

All the details in this publication have been checked and are provided to the best of our knowledge. But just like all technical
recommendations for applications, they are not binding, are not covered by our contractual obligations ( this also applies to copy-
rights of third parties ) and we do not assume liability for them. In particular they are not promises of characteristics and do
not exempt the user from checking the products we supply for suitability for their intended purpose. Reprints, translations and
copies, including extracts, require our express approval. New alloy developments made as technology progresses after printing
are included in later versions. Version 2 – 12/2017

52
 GRUPPE DREI 122017
®
RHEINFELDEN ALLOYS GmbH & Co. KG
A company of the ALUMINIUM RHEINFELDEN group
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