Structure & thin-wall design
Review wall distribution, ribs, connection points and load paths alongside filling distance, draft and ejection. Agree feasible geometry for the selected alloy and tool.
Review structural requirements →
Lightweight components
Magnesium Alloy Die Casting
Magnesium die casting for weight-sensitive components, with alloy, stiffness, corrosion protection and production requirements assessed together.
Project requirements at a glance
Magnesium Casting Project Review
Review the component, material specification and delivery requirements together before selecting tooling and production conditions.
- Design targets
- Target weight · Stiffness · Loads · Assembly requirements
- Alloy specification
- AZ91D is the reference grade here; select the actual grade for the service requirements
- Size & weight
- Subject to drawing, tooling and production-configuration review
- Thin walls & structure
- Wall distribution · Filling distance · Ribs · Local connections
- Protection & interfaces
- Coating system · Mating materials · Joining · Masked surfaces
- Acceptance requirements
- As-cast and machined dimensions · Functional tests · Required records
Magnesium part weight, wall thickness and tolerances are established for the selected grade and geometry. Aluminum or zinc ranges and general machine counts do not establish magnesium capacity. Confirm the mold layout, projected area and production configuration for the actual component.
Lightweight component planning
Weight, Stiffness and Part Geometry
Define the required weight reduction alongside stiffness, load and assembly targets. A material-density comparison alone does not determine the weight of a redesigned component.
A frame illustration provides context for structural review. Its exact grade, manufacturing route and weight reduction are not established by the image.
- 01 · Walls & reinforcing features
- Identify local wall sections, ribs and transitions. Review the geometry needed to meet stiffness and load targets.
- 02 · Mounting & load paths
- Mark fixed interfaces, fasteners, connection points and loads. Identify geometry that may change and dimensions that must remain fixed.
- 03 · Protection & contact surfaces
- Specify mating materials, coating requirements and contact or fit surfaces that need masking or dimensional control.
For review, provide the current material and part weight, target weight, allowable deformation and permitted design changes.
Compare casting alloy families →
Design for the delivered part
Structure, Protection and Production Review
Agree the structure, surface protection and manufacturing conditions as one route. Project capability and the selected alloy are confirmed before a production commitment.
Protection & assembly interfaces
Specify the environment, mating materials and joining method. Review the coating system, masking, fasteners and dimensions before or after treatment.
Plan surface protection →Production & secondary machining
Confirm the alloy, equipment configuration, melt protection, machining route and inspection requirements with process specialists before agreeing production.
Review machining requirements →
Material data & engineering reference
Magnesium Alloy Reference
Material reference values support initial selection. Confirm the specified grade, manufacturing condition and acceptance criteria for the finished component.
Magnesium alloys are candidates for weight-sensitive housings and components. AZ91D is the reference grade used here. Select the grade for the required stiffness, load paths, joining method, surface protection and service conditions.
Still comparing materials? Compare casting alloy families →
Physical and mechanical properties
The following published values refer to AZ91D. Use these values for initial material comparison. Part acceptance and design properties require the applicable specification, delivery condition and representative test evidence.
| Reference property | Value |
|---|---|
| Density | 1.81 g/cm³ |
| Typical tensile strength | 230 MPa |
| Reference Brinell hardness | 75 |
| Approximate melting range | 470–595°C |
NADCA 2021 alloy data, Table A-3-11, page 3-22. The NADCA figures describe separately die-cast, as-cast specimens rather than specimens removed from production parts. Tensile strength is referenced at 20°C; hardness is an average of scattered data.
The melting range describes the solidus-to-liquidus interval. Service limits and casting temperatures must be established separately.
Temperature, corrosion and service conditions
At equal solid volume, AZ91D's reference density gives approximately 33% less mass than A380. Actual weight reduction depends on the geometry needed to meet stiffness and strength requirements. Elevated-temperature or creep requirements may favor another magnesium grade. Specify the operating environment, coating system and contact with other materials.
Casting process and design
Assess thin-wall filling, flow distance, melt protection and equipment configuration together. Confirm the selected alloy, feasible geometry and required process validation before production is agreed.
Melt protection
Molten magnesium requires a suitable protection system to control oxidation. SF₆ has been used in cover-gas mixtures, and alternative technologies exist. Process specialists must evaluate the selected system against the alloy, equipment, safety and environmental requirements. US EPA: magnesium melt protection
Tooling and service life
Thermal fatigue, erosion, local die geometry and maintenance influence useful tool life. Assess the tool design and service-life requirements for the actual production conditions.
Published die-life reference: 100,000–400,000 shots, from the Uddeholm tooling guide, page 12. The range counts casting cycles. Confirm actual tool life and core or insert replacement intervals for the project; the reference is not a service-life commitment.
Surface finishing and machining
Assess conversion coatings, anodic treatments, paint or combined protection systems against the operating environment and assembly interfaces. Magnesium is generally readily machinable, but chips and dust require dedicated handling. Select dry machining or a compatible cutting-fluid process through the process and safety assessment.
Machining safety review
Water-containing cutting fluids require compatibility confirmation and assessment of hydrogen generation, ventilation, corrosion and chip management. Emergency procedures must specify extinguishing media suitable for magnesium metal fires; water and carbon dioxide are unsuitable for burning magnesium chips. Luxfer magnesium machining guide
Agree finish samples, coating thickness, adhesion, corrosion-test conditions and whether dimensions apply before or after treatment. Electrical or thermal contact areas may need defined masking and interface requirements.
Total part cost
Evaluate the value of component weight reduction alongside melt protection, chip handling, surface protection, cycle time and yield. Compare the complete production and finishing sequence at the required quantities.
Compare cost per accepted component, including material utilization and recovery, tooling, production, secondary operations, inspection, rejects, packaging and transport. Energy use also depends on furnace efficiency, holding time and production utilization.
RFQ Requirements
- Controlled drawing and CAD revision, intended use and permitted material substitutions.
- Loads, design life, temperature history, exposure media and target weight.
- Critical dimensions, finish expectations, leakage or electrical/thermal requirements.
- Expected batch and annual volume, required tests and acceptance records.
Confirm alloy, size, mass, tolerances, finish and testing requirements during the drawing and DFM review. Record the agreed manufacturing and acceptance requirements before production release.
Magnesium Casting FAQs
How much weight can magnesium save compared with aluminum?
AZ91D and A380 reference densities indicate approximately 33% less mass at equal solid volume. Actual component mass depends on the geometry required for stiffness, strength, assembly and service life.
How is magnesium melt protection selected?
Process specialists select the protection technology for the alloy and equipment, considering oxidation control, safety and environmental requirements. Alternatives to SF₆-based systems exist.
What must be considered when machining magnesium?
Assess chip and dust handling, tool and fixture design, cutting-fluid compatibility, ventilation and fire precautions. Dry machining and suitable cutting-fluid processes are both possible following the required assessment.
When should a magnesium grade other than AZ91D be reviewed?
AZ91D is the reference grade on this page. If elevated-temperature loading, creep, impact or other service requirements govern the design, review the applicable alloy specification, manufacturing condition and required test evidence before selecting the grade.
What should be supplied for surface protection and mating materials?
Describe the operating environment, exposure media, mating materials and joining method. Identify coating requirements, protected and uncoated surfaces, critical fits and any corrosion or functional acceptance tests.
Can I submit a drawing before selecting a magnesium grade?
Yes. Include the current material and weight, target weight, stiffness and load requirements, temperature, environment, quantities and permitted geometry changes so material and production options can be reviewed together.
Engineering resources
Plan Your Magnesium Casting
Die Casting DFM Checklist Before Tooling Release
A drawing-based checklist for closing geometry, tooling, machining, finishing, inspection, and approval questions before die manufacture begins.
Read engineering guide →How to Select a Surface Finish for Metal Parts
Select and specify finishes for cast and machined parts using material compatibility, service conditions, functional requirements and appearance criteria.
Read engineering guide →What Drives Die Casting Cost? A Total-Cost Review
A practical guide to tooling, material, geometry, process, machining, finishing, inspection, assembly, and change risks that shape total die casting cost.
Read engineering guide →Drawing & project review
Review Your Magnesium Casting Project
Send your drawing with the alloy specification and finished-part requirements. Engineering reviews the proposed route and provides clarification questions, next steps or a quotation.
Review My Magnesium Project →Files are stored privately. Contact us before uploading if your project requires an NDA.
Include with your RFQ
- Controlled drawing and CAD revision; alloy grade and governing standard.
- Batch and annual quantities; target delivery schedule.
- Current material and weight, target weight, permitted geometry changes and fixed interfaces.
- Stiffness, loads, allowable deformation, temperature and operating environment.
- Mating materials, joining method, surface protection, critical dimensions and functional acceptance tests.