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What are the most durable die casting materials for industrial components?

Table of Contents
What Are the Most Durable Die Casting Materials for Industrial Components?
Aluminum Alloys: Strength with Lightweight Efficiency
Zinc Alloys: Toughness and Dimensional Accuracy
Copper-Based Alloys: Extreme Strength and Corrosion Resistance
Recommended Durable Die Casting Materials by Application
Durable Die Casting Services for Industrial Components

What Are the Most Durable Die Casting Materials for Industrial Components?

Aluminum Alloys: Strength with Lightweight Efficiency

Aluminum die casting alloys are widely used in industrial components where a balance of strength, weight, and corrosion resistance is essential. Alloys like A380 and A360 are among the most durable options for structural housings, brackets, and frames. A380 offers good mechanical strength (UTS ~317 MPa) and excellent thermal conductivity, while A360 provides superior corrosion resistance and better ductility, making it ideal for outdoor or chemical plant environments.

For applications involving higher mechanical loads, AlSi10Mg delivers high fatigue strength and wear resistance, critical for dynamic industrial assemblies and high-stress supports.

Zinc Alloys: Toughness and Dimensional Accuracy

Zinc alloys, particularly Zamak 5 and ZA-8, are exceptionally tough and maintain high impact resistance. Zamak 5 has a tensile strength of ~331 MPa and offers superior wear characteristics, making it suitable for industrial levers, actuators, and gearbox components. ZA-8 contains higher aluminum content, enhancing strength and performance in moderately elevated temperatures.

These alloys are also well-suited for high-precision mechanical interfaces due to their excellent dimensional control and casting fluidity, enabling long mold life and consistent tolerances.

Copper-Based Alloys: Extreme Strength and Corrosion Resistance

For the most demanding industrial environments, copper-based die casting alloys offer unmatched durability. Alloys like Aluminum Bronze C95400 and C18200 provide superior mechanical strength (UTS > 500 MPa), excellent wear resistance, and high corrosion resistance—making them ideal for bushings, wear plates, and high-load bearing applications.

C17500, a beryllium copper alloy, combines high thermal conductivity with excellent fatigue resistance, suitable for heavy-duty connectors and tooling inserts under thermal cycling.

Material

Tensile Strength (MPa)

Best For

A380 Aluminum

~317

Industrial enclosures, brackets, structural components

AlSi10Mg

~340

Load-bearing frames, fatigue-prone parts

Zamak 5

~331

High-precision gears, mechanical linkages

ZA-8

~380

Moderate heat-resistant components

C95400 Aluminum Bronze

>500

Wear plates, bushings, valves

C18200 Copper Alloy

>450

Corrosive environments, industrial terminals

Durable Die Casting Services for Industrial Components

For industrial applications requiring high strength, wear resistance, and long service life, Neway offers:

Our full-service capabilities—from tool and die making to post-machining—ensure durability is built into every part.

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