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Magnesium Die Casting

Magnesium is the light-weight champion of all die casting metals.

Magnesium die casting is the logical option if your project requires a lightweight die casting component with an excellent strength-to-weight ratio. CWM die casts magnesium alloy AZ91D, a high-purity alloy that offers good corrosion resistance for your magnesium parts, as well as the following benefits:

  • Longer tool life
  • Easiest alloy to machine
  • Good thermal and electrical conductivity
  • Excellent for thin-wall, complex parts
  • Excellent noise and vibration-dampening properties
  • Provides excellent EMI & RFI shielding
  • Good finishing characteristics
  • Lightweight (75% lighter than steel, 33% lighter than aluminum) with high strength
  • Magnesium parts scrap material is 100% recyclable
Magnesium Kodak Camera Housing
Thinwall, hot-chamber magnesium die casting was used for this Kodak camera housing. It provided exceptional built-in EMI/RFI shielding needed for the design. Magnesium makes it possible to create a thinner profile with the equivalent strength of heavier metals.

What is Magnesium?

MagnesiumMagnesium is a base material for numerous alloys. AZ91D is the most common magnesium alloy for die casting. It offers very good castability and toughness and is ideal for lightweight, highly durable parts.

Hot-Chamber Die Casting - Magnesium

Chicago White Metal uses hot-chamber die casting to produce die cast magnesium parts. In this process, the metal injection components are submerged in a reservoir of molten magnesium. A hydraulically powered piston forces the magnesium into the die, using magnesium’s excellent flow characteristics to produce complex shapes accurately.

Why Choose Magnesium for Your Die Casting Project?

Magnesium Leopold Scope

Compared to steel, magnesium is 75% lighter with no significant loss of strength. It is a far better material for complex, thin-walled, net-shaped, or near-net-shaped castings and offers greater dimensional stability. Magnesium castings can meet tight tolerances that would be difficult or impossible to achieve with steel. Tooling costs can be lower for magnesium castings, as multiple parts can be easily consolidated into a single component. This also improves component rigidity and reduces welding and assembly costs.

When comparing magnesium to aluminum, it is 33% lighter, has similar or improved mechanical properties, and is easier to machine. Magnesium provides greater corrosion resistance and is better suited to large, thin-wall, net-shaped complex parts.

Magnesium Die CastingPrimary Benefit of MgSecondary Benefit of Mg
vs. Steel Weldment75% LighterLess Expensive
vs. Aluminium Die Casting33% LighterLonger Tool Life
vs. Plastic MoldingStronger, stifferEnvironmentally Stable

Magnesium is stronger and stiffer than even the most advanced engineered plastics. It also provides greater wear resistance, higher temperature resistance, and better energy absorption/impact resistance characteristics.

Chicago White Metal was the first hot-chamber magnesium die casting company in North America and operates one of the largest, most advanced facilities for magnesium die casting. With eight magnesium die casting machines with 200 to 650 tons of locking force, CWM can produce magnesium parts in sizes from 0.75″ x 0.75″ to 18″ x 18″.

Request a quote or contact Chicago White Metal to discuss your project.