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Magnesium Die Casting Services

TOPS Precision provides custom magnesium die-casting solutions that fit your company’s production requirements. Since we provide end-to-end solutions to the manufacturing industry, we assure precision in our magnesium die-casting services to produce lightweight, durable, and complex designs. With our best-of-industry machines and a highly skilled workforce, we guarantee that every magnesium part is made with precise quality, durability, and performance.

  • Tolerances of ±0.005 to ±0.010 inches.
  • Lightweight, strong magnesium alloys.
  • Provide customized die-cast parts with high accuracy.
  • Fast, cost-effective production.

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    What is Magnesium Die-Casting?

    Die casting of magnesium belongs to high-pressure casting where molten metal is forced at high pressure into a die to manufacture intricate, high-accuracy parts. Besides this, magnesium is a light metal, quite strong for its weight — which makes it ideal for many industries including the automobile, aircraft industry, electronics, and the medical field where it is used in making instruments. This procedure helps make many detailed parts in large volumes because the accuracy of dimensions and surface finish of certain parts are enhanced making it one of the best methods to use when making magnesium parts. The magnesium die-casting process offers several advantages:

    • High-speed capability of producing a large number of parts
    • Low crosses of post-casting machining due to the castings’ high accuracy.
    • Complex geometries especially when the walls are extremely thin.
    • A good dimensional accuracy for use in durable parts manufacturing

    Magnesium Die Casting Types

    There are two primary types of magnesium die-casting processes:

    Hot Chamber Die Casting

    In comparison, in hot chamber die casting the molten magnesium is held within the casting machines, hence cycle times are quicker. Ideally, it is used on small parts manufacturing applications that need high production speed. Besides this, it is used for components in applications where high-volume production is employed in areas such as consumer electronics and automotive.

    Cold Chamber Die Casting

    Permanent mold die casting on the other hand is called cold chamber die casting where the magnesium is melted in another furnace and then poured into the casting machine just before the injection. Applicable to high-pressure big and complicated workpieces and enjoying better precision than hydraulic presses. Primarily utilized for applications in aerospace, automobile, and several manufacturing industries where requirements are highly stressed components.

    Composition and Applications of Different Magnesium Alloy

    Alloy

    Composition

    Applications

    AZ91D

    Mg, 9% Al, 1% Zn

    Automotive parts, electronics, general casting

    AM60B

    Mg, 6% Al, 0.5% Mn

    Automotive crash components, structural parts

    AM50

    Mg, 5% Al, 0.5% Mn

    Automotive safety parts, thin-walled castings

    AE44

    Mg, 4% Al, 4% Rare Earth

    Engine parts, high-temp applications

    ZM21

    Mg, 2% Zn, 1% Mn

    Aerospace parts, corrosion-resistant components

    AZ63

    Mg, 6% Al, 3% Zn

    General casting, automotive parts

    ZE41

    Mg, 4% Zn, 1% Rare Earth

    Aerospace, racing, helicopter gearboxes

    AS41A

    Mg, 4% Al, 1% Si

    Engine parts, transmission cases

    AX31

    Mg, 3% Al, 1% Ca

    Aerospace, automotive, creep-resistant parts

    MRI 153M

    Mg, 5% Al, 3% Ca

    High-temp engine parts, powertrain components

    Why Magnesium?

    Magnesium is a highly sought-after material in industries due to its unique properties:

    • Lightweight Strength: It weighs 75% less than steel and 33% less than aluminum, meaning that it offers excellent value for applications where the component weight of a part must be considerably decreased without sacrificing strength.
    • Excellent Heat Dissipation: Magnesium components enable perfectly for applications where a component has to deal with thermal control and that could be the applications related to electronic enclosures and automobile parts.
    • Corrosion Resistance: Magneton’s magnesium die-casting process also improves the inherent protecting magnesium features to increase the life of your parts.
    • High Precision and Complex Shapes: With magnesium, one can easily mold many structures with complicated geometries and thin walls, and with a lot of design flexibility and latitude.

    Magnesium Alloy Properties

    The die-cast magnesium alloys are important for providing lightweight, strength, and multi-directionality. Below is a table detailing the typical properties of popular magnesium alloys used in die casting:

    Alloy

    Density (g/cm³)

    Yield Strength (MPa)

    Tensile Strength (MPa)

    Elongation (%)

    Corrosion Resistance

    Melting Point (°C)

    Thermal Conductivity (W/mK)

    AZ91D

    1.81

    160

    230

    3

    Excellent

    595

    72

    AM60B

    1.80

    125

    240

    10

    Good

    615

    80

    AM50

    1.77

    110

    220

    12

    Good

    620

    85

    AE44

    1.84

    165

    255

    8

    Very Good

    640

    76

    ZM21

    1.79

    150

    250

    15

    Good

    660

    90

    AZ63

    1.82

    140

    200

    5

    Good

    620

    75

    ZE41

    1.80

    145

    245

    6

    Moderate

    620

    85

    AS41A

    1.77

    130

    200

    4

    Good

    610

    60

    AX31

    1.78

    130

    230

    9

    Very Good

    590

    70

    MRI 153M

    1.79

    140

    220

    6

    Excellent

    635

    68

    Our Capability of Magnesium Die Casting services

    At TOPS Precision we avail the latest technology and vigorously follow quality measures to offer excellent magnesium die-casting services to the customers. Our offerings include:

    Custom Die Casting Mold Making

    For magnesium die casting, we design customized cores to allow bright and accurate dimensions to be achieved on mass production.

    High-Volume Production

    We are ideally positioned to address your manufacturing concerns including prototype production, low-volume production, high-volume production, or any other manufacturing.

    Post-Casting Services

    Comprehensive services but not limited to machining, surface finishing, and assembly services for your products to be ready for use as soon as they get to your premises.

    Industries We Serve

    Our magnesium die-casting services cater to a variety of industries:

     

    • Automotive: Components for achieving good fuel efficiency and improved vehicle performance.
    • Aerospace: Light and strong components for better flight.
    • Electronics:Accurate parts for both cooling purposes and mechanical support.
    • Medical Devices:Magnesium-based parts for medical instruments that are lightweight as well as strong.

    Why TOPS Precision for Magnesium Die Casting Services?

    8

    Unmatched Precision

    Our professional staff ensures that all parts are cast to the highest level of accuracy for the best and most dependable performance.
    9

    Cost-Effective Solutions

    We blend technology and optimum procedures to deliver premium-quality magnesium die casting at an acceptable cost.
    10

    ISO 9001:2015 Certified

    Our company meets the highest international quality management systems standards so that the parts we produce meet the required quality and safety levels

    Contact Us

    Are you ready to grow your production with the best magnesium die-casting services? Reach out to TOPS Precision today for a consultation and get a quote. Consult our team of specialists for any project: prototype and full-scale production.

    Send Your Inquiry Today

      Get Your Quote Today!

      Frequently Asked Questions

      Die-casting with magnesium is a molten magnesium alloy that results in high-strength yet lighter parts. It has shorter production cycles than aluminum or zinc casting, and it has even improved corrosion properties.

      Magnesium die casting can be used in automobile, aerospace, electronics, and medical sectors because of their lightweight and high strength.

      Magnesium die-casting components are AZ91D, AM60B, and AE44. They’re developed for certain mechanical characteristics.

      Yes, magnesium die-casting components have high accuracy with numerous undercuts. Besides this, it applies to the custom parts requirements that contain complicated profiles

      The recovery is easy and this metal can be recycled more times than any other metal; the energy used in the manufacture of magnesium is lower than the energy used in other metal manufacturing, i.e. aluminum.

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