EN AC-43500 (AlSi10Mg)

Alternative Material Options

When design requirements extend beyond the capabilities of EN AC-43500, several alternatives may be considered. For higher strength and improved thermal fatigue resistance, copper-containing alloys such as EN AC-46000 (AlSi9Cu3) deliver enhanced structural performance for automotive powertrain applications. If ultra-high wear resistance is required, A390 provides exceptional hardness. For general-purpose die casting with balanced cost and castability, A380 or ADC12/A383 remain industry standards. When weight reduction and superior corrosion resistance are primary objectives, magnesium-containing and low-copper alloys offer an advantage. For premium aesthetics or conductivity, copper-based materials such as copper-brass alloys or Brass 380 are suitable alternatives where visual quality outweighs density constraints.

International Equivalent / Comparable Grade

Design Purpose

EN AC-43500 (AlSi10Mg) was originally designed for lightweight structural castings that require improved elongation, high fatigue strength, and reliable dimensional consistency. With its magnesium-modified Al–Si eutectic system, the alloy delivers a refined microstructure that enhances ductility and weldability, making it suitable for load-bearing brackets, crash-relevant components, and thermally stable housings. Its low porosity potential and good thermal conductivity enable consistent filling of thin-wall sections without excessive shrinkage defects. The alloy is particularly effective for components that require consistent mechanical behavior over a wide range of temperatures, such as lighting housings, automotive structural parts, actuators, and precision mechanical modules.

Chemical Composition

Physical Properties

Mechanical Properties

Key Material Characteristics

• Excellent fluidity for thin-wall components and complex ribs.

• Higher ductility and fatigue resistance than Cu-containing alloys.

• Superior corrosion resistance due to low copper content.

• Stable thermal behavior suitable for precision housings.

• Improved weldability for multi-part assemblies or repairs.

• Fine microstructure with low porosity when processed correctly.

• Good compatibility with machining and surface finishing.

• Low density ideal for weight-optimized structural components.

• High repeatability in medium- and high-volume die casting.

Manufacturability And Post Process

• High-Pressure Die Casting (HPDC) for lightweight structures: EN AC-43500 is ideal for HPDC because its Si–Mg system delivers predictable filling characteristics and reduced hot tearing. Thin walls down to ~1.2–1.5 mm can be filled reliably using well-balanced runner systems and controlled die temperatures.

• Vacuum-assisted HPDC for high ductility: Vacuum gating significantly reduces oxides and entrapped gas—critical for achieving the high elongation this alloy is capable of.

• Heat treatment compatibility: Unlike high-copper alloys, AlSi10Mg can be artificially aged (T5/T6) to improve strength and fatigue performance, depending on casting geometry and porosity control.

• CNC machining and secondary finishing: With stable hardness and fine eutectic structure, EN AC-43500 machines cleanly on CNC machining platforms. Neway’s precision post machining ensures dimensional tolerances of ±0.02–0.05 mm.

• Threading, drilling, and reaming: Excellent chip formation and minimal tool buildup allow for clean threads, accurate drilled holes, and tight-tolerance dowel positions.

• Tumbling and surface smoothing: Components are processed with tumbling or vibratory finishing to remove edges and enhance coating adhesion.

• Dimensional and functional inspection: High-precision housings and safety-critical parts are validated through CMM, leak testing, and additional checks via Neway’s die castings inspection systems.

Suitable Surface Treatment

• Anodizing for decorative and corrosion-resistant finishes: EN AC-43500’s low copper content makes it significantly better suited for anodizing compared to copper-rich alloys. Uniform matte or satin colors can be achieved with proper pre-treatment.

• Powder coating for mechanical durability: Powder coating offers excellent UV and corrosion protection while adding impact resistance for outdoor enclosures.

• Liquid painting for aesthetic components: Painting enables detailed color customization for consumer goods and industrial housings.

• Conversion coatings for improved adhesion: Chromate and Cr-free conversion coatings form uniform conductive layers ideal for electronic housings and pre-paint adhesion.

• Sanding and bead-blasting: Controlled sand-blasting produces a clean matte texture that hides small casting irregularities and enhances surface uniformity.

• Laser marking: Permanent, high-contrast marking is possible while maintaining dimensional stability of thin-wall components.

Common Industries and Applications

• Automotive lightweight structural modules and brackets.

• LED lighting housings and heat-dissipating frames.

• Precision actuators and mechanical components.

• Consumer electronics shells and structural carriers.

• Aerospace and UAV lightweight components.

• General engineering parts requiring high fatigue resistance.

When to Choose This Material

• When high ductility and fatigue strength are essential.

• When thin-wall lightweight components must maintain dimensional stability.

• When components require anodizing or premium cosmetic finishes.

• When corrosion resistance is a priority over extreme strength.

• For welded assemblies or structural joints requiring metallurgical compatibility.

• For parts requiring temperature stability in environments ranging from 80 to 150 °C.

• For applications requiring tight tolerances that can be achieved with CNC finishing.

• For medium- to high-volume production with consistent casting repeatability.