Alloy 365.0 and A365.0 are developed near eutectic Al-Si die-casting alloys with additions of manganese to reduce die soldering. This datasheet provides information on key alloy metallurgy, processing effects on tensile properties, and fabrication characteristics of these 3xxx series alloys.

The aluminum alloys 367.0 and 368.0 are high-performance, low-iron, die-casting alloys that rely on strontium for die soldering resistance. In these alloys, the lower iron content minimizes the formation of needle-like, Al-Fe-Si phases that can deteriorate strength, elongation and fatigue behavior. This datasheet provides information on key alloy metallurgy, processing effects on tensile properties, and fabrication characteristics of these 3xxx series alloys.

Alloy 362.0, low-iron premium die-casting alloy, is made from recycled secondary metal scrap and was developed to have equivalent or better mechanical properties than Silafont-36 and/or Aural-2. This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, and applications of this alloy.

This article summarizes some general alloy groupings by application or major characteristics. The groupings include cast rotor, general-purpose, elevated-temperature, wear-resistant, moderate-strength, high-strength, and high-integrity die casting alloys and cast aluminum alloys bearings. A table lists selected applications for aluminum casting alloys.

Aluminum casting alloys are the most versatile of all common foundry alloys and generally have the highest castability ratings. This article provides an overview of the common methods of aluminum shape casting. These include gravity casting, die casting, sand casting, lost foam casting, shell mold casting, plaster casting, investment casting, permanent mold casting, squeeze casting, semisolid forming, centrifugal casting, and pressure die casting. The article presents several different factors on which the selection of a casting process depends. It discusses gating and risering principles in casting. The article concludes with information on premium engineered castings that provide higher levels of quality and reliability than in conventionally produced castings.

Aluminum casting alloys are the most versatile of all common foundry alloys and generally have the highest castability ratings. This article discusses the designation and classification of aluminum casting alloys based on their composition and the factors influencing alloy selection. Alloys discussed include rotor alloys, commercial duralumin alloys, premium casting alloys, piston and elevated-temperature alloys, general-purpose alloys, magnesium alloys, aluminum-zinc-magnesium alloys, and bearing alloys. Six basic types of aluminum alloys developed for casting include aluminum-copper, aluminum-copper-silicon, aluminum-silicon, aluminum-magnesium, aluminum-zinc-magnesium, and aluminum-tin. The article also describes the main casting processes for aluminum alloys, which include die casting, permanent mold casting, sand casting (green sand and dry sand), plaster casting, and investment casting. In addition, the article discusses factors affecting the mechanical and physical properties, microstructural features that affect mechanical properties, the effects of alloying, and major applications of aluminum casting alloys.

Aluminum casting alloys are the most versatile of all common foundry alloys and generally have the highest castability ratings. Aluminum alloy castings are routinely produced by pressure-die, permanent-mold, green and dry-sand, investment, and plaster casting. This article describes factors affecting the selection of casting process and the general designation system for aluminum alloys. It provides useful information on mechanical test methods, selection of proper test specimens for accurate test methods, characteristics of premium engineered castings, and advantages of hot isostatic pressing.

This article aims to comprehensively review and summarize the material properties and engineering data for aluminum alloy castings and their many applications. The discussion focuses on conventional sand, permanent mold, and die castings as well as the premium engineered versions of some alloys. The article provides a summary of aluminum casting alloy designations of The Aluminum Association, the Unified Numbering System, and specific alloys considered premium strength by definition and by ASTM International and Aerospace Material Specifications. A distillation of data from published industry sources is given for a wide range of the properties and performance characteristics for topics such as: physical and thermophysical properties, typical and minimum mechanical properties, fatigue resistance, fracture resistance, and subcritical crack growth.

This article begins with a discussion on the effects of alloying and impurity elements on the properties of aluminum cast alloys and their chemical compositions. It describes the various means of structural control, namely, chemistry control, control of element ratios based on the stoichiometry of intermetallic phases, and control of solidification conditions. The article discusses the modification and grain refinement of aluminum-silicon alloys by the use of modifiers and refiners to influence eutectic and hypereutectic structures in aluminum-silicon alloys. It provides information on foundry alloys for specific casting applications. The article concludes with a discussion on the heat treatment practices and properties of aluminum casting alloys.

This article discusses the categories and subcategories of shape casting processes. These include single-use processes such as sand, plaster, ceramic, and graphite molding; essentially unpressurized multiuse processes, such as permanent mold; and high-pressure metal mold methods, such as die casting, squeeze casting, and semisolid processing. The article contains tables that compare some of the typical capabilities of shape casting processes.

Aluminum casting alloys are among the most versatile of all common foundry alloys and generally have high castability ratings. This article provides an overview of the common methods of aluminum shape casting. It discusses the designations of aluminum casting alloys categorized by the Aluminum Association designation system. The article summarizes the basic composition groupings of aluminum casting alloy and discusses the effects of specific alloying elements and impurities. The characteristics of the important casting processes are summarized and compared in a table. The article presents the advantages and disadvantages of green sand casting, permanent mold casting, semipermanent mold casting, and high-pressure die casting. A discussion on other casting processes, such as investment casting, lost foam, plaster mold casting, pressure casting, centrifugal casting, and semisolid casting, is also included.

This article provides information on the applications of metal-matrix composites in engine components, brake system, and driveshaft. The components include pistons, cylinder liners, valves, pushrods, and connecting rods.

Semisolid casting is a near-net shape manufacturing process capable of producing thick- and thin-walled complex-shaped components having excellent mechanical and functional performance. This article begins with a discussion on the history of semisolid processing and the advantages claimed for semisolid casting. It describes the four notable processes used to produce semisolid castings: thixocasting, rheocasting, thixomolding, and wrought processes. Most commercial aluminum semisolid casters use either thixocasting or rheocasting. The article discusses the die design, process conditions, and simulation for semisolid casting. It concludes with a review of several components produced by each of the various semisolid casting processes.

Aluminum alloys are primarily used for nonferrous castings because of their light weight and corrosion resistance. This article discusses at length the melting and metal treatment, structure control, sand casting, permanent mold casting, and die casting of aluminum alloys. It also covers the types and melting and casting practices of copper alloys, zinc alloys, magnesium alloys, titanium alloys, and superalloys, and provides a brief account on the casting technique of metal-matrix composites.

This article focuses on heat treating of the most important H-series and low-alloy hot-work tool steels, namely, normalizing, annealing, stress relieving, preheating, austenitizing, quenching, tempering, and surface hardening. It describes the heat-treating procedure for hot-work tools using examples. The article provides information on the North American Die-Casting Association's requirements for steel grades and heat treatment of dies made of hot-work tool steels. It also describes the chemical compositions and mechanical and metallurgical properties of hot-work tool steels.

This article reviews the melt processing and casting of non-ferrous alloys, such as nickel alloys, titanium alloys, and lead alloys. It describes the lead refining steps, namely, copper drossing, softening, desilvering, zinc removal, bismuth removal, and final refining.

This article discusses the concepts underlying linear elastic fracture mechanics and elastic-plastic fracture mechanics as well as their importance in characterizing the fracture behavior of the high-strength aluminum alloys. It describes the three methods used for analyzing elastic-plastic fracture, namely R-curve concept, J-integral concept, and crack tip opening displacement method. The article considers the primary measures used to assess the toughness of aluminum alloy castings and wrought alloys: notch toughness, tear resistance, and plane-strain fracture toughness.

This article focuses on the general root causes of failure attributed to the casting process, casting material, and design with examples. The casting processes discussed include gravity die casting, pressure die casting, semisolid casting, squeeze casting, and centrifugal casting. Cast iron, gray cast iron, malleable irons, ductile iron, low-alloy steel castings, austenitic steels, corrosion-resistant castings, and cast aluminum alloys are the materials discussed. The article describes the general types of discontinuities or imperfections for traditional casting with sand molds. It presents the international classification of common casting defects in a tabular form.

This article is a comprehensive collection of tables that list the values for hardness of plastics, rubber, elastomers, and metals. The tables also list the tensile yield strength and tensile modulus of metals and plastics at room temperature. A comparison of various engineering materials, on the basis of tensile strength, is also provided.

This article focuses on the variety of alloys, furnaces, and associated melting equipment as well as the casting methods available for manufacturing magnesium castings. These methods include sand casting, permanent mold casting, die casting, thixomolding, and direct chill casting. The article discusses the flux process and fluxless process for the melting and pouring of magnesium alloys. It describes the advantages and disadvantages of green sand molding and tabulates typical compositions and properties of magnesium molding sands. The article provides information on the machining characteristics of magnesium and the applications of magnesium alloys.