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Alu Rheinfelden

high pressure die casting Magsimal™-59

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<font face="Arial, Helvetivca" size="2">In 1996 an alloy was presented from <strong>Aluminium Rheinfelden GmbH</strong> to the market which was unusual for high pressure die casting at that time: the AlMgSi-type <strong>Magsimal™-59</strong>. So far this type of alloy type had been mainly used for permanent mould casting and was especially known for its excellent resistance to corrosion even in sea water. However in addition to that it offers further properties and abilities when used in high pressure die casting which make it superior to many other alloys. The chemical composition is AlMg5Si2Mn-based. Other than most alloys for high pressure die casting <strong>Magsimal™-59</strong> contains five to six percent Magnesium and roughly two percent of Silicon. A surplus of Magnesium and low Copper and Zinc contents maintain the excellent resistance to corrosion. Iron is kept low to keep up the elongation. Beryllium is added to reduce dross during the melting process. Together with a quick solidification a very fine microstructure consisting of an -solid solution and 40% Mg2Si-eutectic is created with superior mechanical and fatigue properties in temper F. As the fineness of the microstructure depends on the solidification velocity the geometry of the casting has huge influence on the mechanical properties.</font>

<font face="Arial, Helvetivca" size="2">The thinner the wall thickness is, the higher both yield strength and elongation are. At a wall thickness of 4 mm a fatigue strength of 100 MPa for tension-compression is reached. </font>

<font face="Arial, Helvetivca" size="2">For the designing engineer this behaviour of increasing properties with decreasing wall thickness has advantages, because a thin and light design promotes the performance of the material. However a some recommendations looking at the complexity of the design have to be taken in to account due to the higher shrinkage of this alloy type. The die design requires larger radiuses and drafts compared to an AlSi-type. None the less <strong>Magsimal™-59</strong> with its excellent properties in temper F may substitute applications in AlSi requiring a heat treatment causing distortion and straightening of the parts. </font>

<font face="Arial, Helvetivca" size="2"><strong>Applications in Magsimal™-59</strong></font>

<font face="Arial, Helvetivca" size="2"><strong>Magsimal™-59</strong> is an excellent material for die castings which have to resist high static and alternating loads and provide a good ductility at the same time. Typical applications are structural and suspension parts in passenger cars. Next figure shows the shock tower of an upper middle class car with a completely new concept.</font>

<font face="Arial, Helvetivca" size="2">With the goal to spread the weight of the vehicle evenly on front and back wheels, the front subframe is entirely designed in Aluminium. The shock tower is a structural part where the suspension strut is connected. So this part has to resist the static load from the car weight and the dynamic shocks coming from the suspension. The part is designed with thin wall thickness to receive the required yield strength and at the same time providing a high elongation for a good crash behaviour. The cast part is connected to the surrounding profiles and wrought Aluminium parts by gluing, self-pierce-riveting and MIG-welding. Due to the excellent corrosion resistance the part does not require a paint coating.</font>

<font face="Arial" color="#0000ff" size="2"><font face="Arial, Helvetivca" color="#000000" size="2">For more information about <strong>Magsimal(tm)-59</strong>, our other innovative products and services, visit our homepage at: </font><a href="" target="_blank">&lt;font face="Arial, Helvetivca" size="2"&gt;&lt;/font&gt;</a><font face="Arial, Helvetivca" size="2"><a href="" target="_blank" class="external-link-new-window"><img src="" alt></a></font><font face="Arial, Helvetivca" color="#000000" size="2">, or contact one of our engineers directly: Dipl.-Ing. Ralf Klos, phone: +49 7623 93-407, fax: +49 7623 93-546</font></font>

<font face="Arial, Helvetivca" size="2">Aluminium Rheinfelden GmbH<br>Rheinfelden Alloys<br>Sales and Customer Service<br>Friedrichstraße 80<br>79618 Rheinfelden - Germany<br><a href="" target="_blank" class="external-link-new-window"><img src="" alt> </a></font>

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