The metals used for die casting mainly include zinc, copper, aluminum, magnesium, lead, tin, and lead-tin alloys. Although die-cast iron is rare, it is also feasible. More special die-cast metals include ZAMAK, aluminum-zinc alloys and the standards of the Aluminum Association of America: AA380, AA384, AA386, AA390 and AZ91D magnesium. The characteristics of various metals are as follows:
Zinc: The easiest metal to die-cast, it is economical to manufacture small parts, easy to coat, high compressive strength, high plasticity, and long casting life.
Aluminum: Lightweight, complex manufacturing and thin-walled castings have high dimensional stability, strong corrosion resistance, good mechanical properties, high thermal and electrical conductivity, and high strength at high temperatures.
Magnesium: Easy to be machined, high strength-to-weight ratio, the lightest among commonly used die-cast metals.
Copper: High hardness, strong corrosion resistance, the best mechanical properties of commonly used die-casting metals, wear resistance, and strength close to steel.
Lead and tin: high density, high dimensional accuracy, can be used as special anti-corrosion parts. For public health considerations, this alloy cannot be used as food processing and storage equipment. The alloy of lead, tin and antimony (sometimes containing a bit of copper) can be used to make manual type and bronzing in letterpress printing.
The upper mass limits for die-casting using aluminum, copper, magnesium, and zinc are 70 lb (32 kg), 10 lb (4.5 kg), 44 lb (20 kg), and 75 lb (34 kg), respectively.
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