World-class aluminum and zinc die cast products



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Process Development and Monitoring

Wilkast engineers utilize Die Cast Process Planner (DCPP) software to design our gating / feed systems; this data is then used during the die build process which greatly improves first shot success.

During the product launch process we create our process map using the DCPP data to set our process baseline utilizing our shot monitoring equipment (Visi-trak).  

Our engineers and manufacturing staff use the Visi-trak software to continuously monitor the critical process parameters during production and constantly compare back to the initial DCPP model. This enables us to eliminate variation within the process.  We understand that “quality” is engineered into the part process, not a hopeful outcome.


  Aluminum Die Casting Alloys Zinc Die Casting Alloys
  A360 A380 383 B390 A413 518 #2 #3 #5 #7 ZA-8 ZA-12 ZA-27
Ultimate Tensile Strength (ksi) 46 47 45 46 42 45 53 41 48 41 54 59 62
Tensile Yield Strength (ksi) 24 23 22 36 19 28 41 32 39 32 41-43 45-48 52-55
Compressive Yield Strength ( ksi) - - - - - - 93 60 87 60 37 39 52
Elongation (% in 2") 3.5 3.5 3.5 <1 3.5 5.0 7 10 7 13 6-10 4-7 2.0-3.5
Hardness(BHN) 500kg load 10mm ball 75 80 75 120 80 80 100 82 91 80 100-103 95-105 116-122
Shear Strength, (ksi) 26 27 - - 25 29 46 31 38 31 40 43 47
Impact Strength ft-lb ASTM .25" die cast bar - 3 3 - - 7 35 43 48 43 24-35 15-27 7-12
Fatigue Strength (ksi)(Rotary Bent 108) 18 20 21 20 19 20 8.5 6.9 8.2 6.9 15 - 21
Young's Modulus  ( psi x 106) 10.3 10.3 10.3 11.8 - - 12.4 12 11.3
  Aluminum die casting alloys Zinc die casting alloys
  A360 A380 383 B390 A413 518 #2 #3 #5 #7 ZA-8 ZA-12 ZA-27
Density (lbs./in3) 0.095 .098 .099 .098 .096 .093 .24 .24 .24 .24 .227 .218 .181
Melting Range (°F) 1035-1105 1000-1100 960-1080 950-1200 1065-1080 995-1150 715-734 718-728 717-727 718-728 707-759 710-810 708-903
Specific Heat BTU/ lb °F 0.230 0.230 0.230 - 0.230 - .10 .10 .10 .10 .104 .107 .125
Coefficient of Thermal Expansion (µ in./in. °F X 10-6) 11.6 12.1 11.7 10.0 11.9 13.4 15.4 15.2 15.2 15.2 12.9 13.4 14.4
Thermal Conductivity   (BTU / ft hr °F) 65.3 55.6 55.6 77.4 70.21 55.6 60.5 65.3 62.9 65.3 66.3 67.1 72.5
Electrical Conductivity (% IACS) 29 23 23 27 31 24 25.0 27.0 26.0 27.0 27.7 28.3 29.7
Poisson's Ratio .33 .33 .33 - - - .30 .30 .30 .30 .30 .30 .30

 

  Aluminum alloy chemical specifications (% by weight) Zinc alloy chemical specifications (% by weight)
  A360 A380 383 B390 A413 518   #2 #3 #5 #7 ZA-8 ZA-12 ZA-27
Silicon (Si) 9.0-10.0 7.5-9.5 9.5-11.5 16.0-18.0 11.0-13.0 .35 Aluminum (Al) 3.9-4.3 3.9-4.3 3.9-4.3 3.9-4.3 8.2-8.8 10.8-11.5 25.5-28.0
Iron (Fe) 1.3 2.0 1.3 1.3 1.3 1.8 Magnesium (Mg) .025-.05 .03-.06 .03-.06 .01-.02 .02-.03 .02-.03 .012-.02
Copper (Cu) .6 3.0-4.0 2.0-3.0 4.0-5.0 1.0 .25 Copper (Cu) 2.7-3.3 .10 .7-1.1 .10 .9-1.3 .5-1.2 2.0-2.5
Manganese (Mn) .35 .50 .50 .50 .35 .35 Iron (Fe) .035 .035 .035 .075 .035 .05 .07
Magnesium (Mg) .4-.6 .30 .10 .45-.65 .1 7.5-8.5 Lead (Pb) .004 .004 .004 .002 .002 .005 .005
Nickel (Ni) .5 .5 .3 .10 .5 .15 Cadmium (Cd) .003 .003 .003 .002 .005 .005 .005
Zinc (Zn) .5 3.0 3.0 1.5 .5 .15 Tin (Sn) .0015 .0015 .0015 .0010 .002 .002 .002
Tin (Sn) .15 .35 .15 - .15 .15 Nickel (Ni) - - - .005-.020 - - -
Titanium (Ti) - - - .10 - - Zinc (Zn) Bal. Bal. Bal. Bal. Bal. Bal. Bal.
Others (each) - - - .10 - -                
Others (Total) .25 .50 .50 .20 .25 .25                
Aluminum (Al) Bal. Bal. Bal. Bal. Bal. Bal.