NADCA Product Specification Standards For Die Casting

NADCA Product Specification
Standards for Die Casting

Aluminum,
Aluminum-MMC,
Copper,
Magnesium,
Zinc and
ZA Alloys
NORTH AMERICAN
AMERICAN DIE
DIE CASTING
CASTING ASSOCIATION
ASSOCIATION
NORTH
Arlington Heights, Illinois
Revised for 2015

9 th Edition
NADCA Product Specification

Standards for Die Casting
Dedicated
to Continuous
Improvement
The North American Die Casting Associations mission is

to continue as the worldwide leader in stimulating growth
and improvement in the die casting industry.
NORTH AMERICAN DIE CASTING ASSOCIATION
For complete information on NADCA corporate or individual membership, contact:
North American Die Casting Association
3250 N. Arlington Heights Rd., Ste. 101
Arlington Heights, IL 60004
Phone: 847.279.0001
Fax: 847.279.0002
Email: [email protected]
Website: www.diecasting.org
Design Website: www.diecastingdesign.org
OEM product engineers and specifiers can contact NADCA for information on a range of
materials and services aimed at helping designers achieve product cost reductions and performance improvements through todays advanced die casting technology. These include an OEM
design, specification and sourcing website, design engineering publications and a regional and
on-site OEM design seminar program.
Product Standards Disclaimer

The standards and guidelines for the specification of products to be produced as die castings
presented in this volume are generic in nature. They are offered as a convenient reference for the
general direction of die casting component designers and specifiers, whose final decisions must
depend on their own engineering and design judgment and predictive testing under application
conditions. Use of these standards and guidelines is voluntary.
The unique characteristics and features of a specific die cast component design are the major determinants of the final specifications which can be economically achieved by the die casting process.
The OEM product engineer is urged to consult with their die caster to establish more precisely
those guidelines which can be expected to apply to a particular design under consideration.
Although every effort has been made to assure accuracy of the data presented, the publisher
cannot be responsible for results obtained through the use of this data.
The North American Die Casting Association, and its members expressly disclaim any liability
arising out of the use of this material.
No warranties, expressed or implied, are given in connection with the accuracy or completeness of this publication. The data presented are subject to modification without notice.
Revisions and Additions Schedule

NADCA Product Specifications Standards for Die Castings will be revised as needed on a yearly
basis. Major revisions and additions are incorporated on a three (3) year schedule.
Published by:
North American Die Casting Association
3250 N. Arlington Heights Rd., Ste. 101
Arlington Heights, IL 60004
Copyright 1994, 1995, 1997, 2000, 2003, 2006, 2009, 2012, 2015
All rights reserved. Printed in the United States of America
Library of Congress Catalog Card Number 94-70763
ISBN 1-885271-00-x
ii
NADCA Product Specification Standards for Die Castings / 2015
N A DC A Pr o d uc t S p ec i f ic a t io n
S t a n d a r ds f o r D ie C as t i n g
Section
Number
Content
iv
Introduction
Cross Reference to NADCA Standards,

Guidelines & Checklists
vii
List of NADCA Standards, Guidelines and Checklists
viii
Current Revisions and Additions
Process and Material Selection for Product Recyclability
Tooling for Die Casting
Alloy Data
4A
Engineering & Design: Coordinate Dimensioning
4B
Engineering & Design: Miniature Die Casting
Engineering & Design: Geometric Dimensioning
Engineering & Design: Additional Specification Guidelines
Quality Assurance
Commercial Practices
Casting Examples
10
Index/ Glossary of Die Casting Terms
1
2
3
4A
4B
5
6
7
8
9
10
iii
Introduction to this Manual
iv
hese specification guidelines and standards for die castings have been formulated to aid
product designers and specifiers in the successful execution of their designs as die cast
components. Significant advances in the capabilities of North American process technology,
and the introduction of an expanded number of die casting alloys, have created new opportunities for
cost-effective die cast designs. To achieve net-shape or near net-shape components, designers today are
using die casting to capitalize on improved dimensional accuracy and stability, cosmetic surface quality,
and more dependable product performance. To best capitalize on all of these advantages, designers and
specifiers should consult the guidelines presented here at an early design stage, in collaboration with a
qualified die caster.
Todays die casting process can offer significant reduction in, or elimination of, part machining costs
through its ability to cast dimensions, holes and features to precision tolerances at high volumes. Such
major cost reductions can also often make die castings practical in lower production volumes. Through
parts consolidation, die castings can reduce finished product assembly costs and improve product
integrity and operation. Selected alloys can allow bearing properties to be integrally incorporated into a
part, eliminating the need for inserts. The established strength and durability of die castings can allow
undamaged disassembly, refurbishing or remanufacture to extend a products useful life. And at the end
of a products life cycle, die castings allow for optimum reclamation with eventual remelting and realloying, followed by die casting back into high-level applications without degradation of properties.
The first section of this manual, Process & Material Selection for Product Recyclability, presents the
facts on this important new product requirement for process and material selection.
The Tooling Section will familiarize engineers, especially those new to the process, with the unique
characteristics of die casting tooling requirements.
The Alloy Data Section provides an updated reference to die casting materials commercially available
for component design specification in North American production. These material families include
the aluminum alloys; aluminum metal matrix composites; copper alloys including brass and bronze;
magnesium alloys; zinc (Zamak) alloys; and zinc-aluminum (ZA) alloys. Lead and tin are rarely die
cast because of relatively low mechanical properties. Ferrous-metal die casting is carried out on a limited
production basis, with very high melting temperatures necessitating the use of special refractory metals
for dies and other special procedures. Alloy tables provide data for comparison of chemical composition and properties for each alloy and their characteristics in die casting and post-casting operations.
Poissons Ratio, where available, is included to aid finite element analysis (FEA).
* Different sets of properties can be achieved with alternate processes (such as high vacuum, squeeze,
and semi-solid casting) and alternate alloys (such as A356, Aural 2 or 356, and Silafont 36). Information on these processes and alloys can be found in the Product Specification Standards for Die castings
produced by Semi-Solid and Squeeze Cast Processes (NADCA Publication #403) and the High
Integrity Die Castings book (NADCA Publication #404).
Replacing the former ADCI/NADCA E Series are the comprehensive Engineering and Design
Sections. These present die casting coordinate dimensioning specifications for Standard Tolerances
and Precision Tolerances, with values up to 65% tighter than the former E Series. In addition,
guidelines for Geometric Dimensioning are presented as they relate to die casting part designs.
Sections on Quality Assurance and Commercial Practices will aid the specifier and die caster in
reaching agreement on the procedures and practices that should be followed to assure purchaser
satisfaction.
A detailed contents page appears at the beginning of Sections 2 through 9. A listing of all numbered
standards, guidelines, and checklists appears on the next page. An index and glossary of die casting
terms appear in Section 10.
More than one section should be reviewed in making process decisions. The special features and
geometry of an individual component to be die cast, its dimensional, functional, finishing and end-use
requirements considered in relation to production parameters must be carefully weighed.
The appropriate tooling, engineering and quality assurance guideline information provided should
be evaluated in combination with alloy data. The benefits of early consultation with an experienced die
caster are obvious.
These guidelines are prepared and published by NADCA, in collaboration with OEM engineers
and dedicated die casting industry technical specialists. Thanks go to the many industry members who
contributed at various stages to the development, research, organization and review that resulted in this
volume.
NADCA wishes to acknowledge the Product Standards Task Force for the efforts provided to
establish this 8th Edition.
G u i d e l i n e & C h ec k l is t
C r oss Re f e r e nc e
Cross Reference between former ADCI Product Standards, former NADCA Volume 401 Product
Guidelines and NADCA 2012 Product Specification Standards for Die Casting.
ADCI
NADCA #401
NADCA 2015
Subject
ADCI-M2
NADCA-M2
NADCA A-3-1
NADCA A-3-2
Composition & Properties of

Standard Aluminum Alloy Die Castings
ADCI-M3
NADCA-M3
NADCA A-3-1
NADCA A-3-2

Special Aluminum Alloy
ADCI-M4
NADCA-M4
NADCA A-3-3
Characteristics of
Aluminum Alloys
ADCI-M5
NADCA-M5
NADCA A-3-7
NADCA A-3-8

Copper Alloy Die Castings
ADCI-M6
NADCA-M6
NADCA A-3-9
Characteristics of
Copper Alloys
ADCI-M7
NADCA-M7
NADCA A-3-10
NADCA A-3-11

Mg Alloy Die Castings
ADCI-M8
NADCA-M8
NADCA A-3-12
Characteristics of
Mg Alloy Die Castings
ADCI-M9
NADCA-M9
NADCA A-3-13
NADCA A-3-14

Zn. & ZA Alloy Die Castings
ADCI-M10
NADCA-M10
NADCA A-3-15
Characteristics of
Zn. & ZA Alloy Die Castings
ADCI-M11
NADCA-M11
(Discontinued)
ADCI-C1-76
NADCA-C1-88
Comml Practices
pgs. 8-8
Production Part Orders
ADCI-C2-76
NADCA-C2-88
Comml Practices
pg. 8-3
Specifying Tolerances
ADCI-C3-76
NADCA-C3-88
Comml Practices
pg. 8-4
Die Casting Dies & Production Tooling
ADCI-C4-79
NADCA-C4-88
Comml Practices
pg. 8-11
Price Adjustments
ADCI-C5-76
NADCA-C3-88
NADCA-C5-88
Comml Practices
pgs. 8-7
Insert: Gauges
ADCI-C6-76
NADCA-C6-88
Comml Practices
pg. 8-12
Patent Obligations
ADCI-C7-76
NADCA-C7-88
Comml Practices
pg. 8-12
Warranties
ADCI-C8-76
NADCA-C8-88
Comml Practices
pgs. 8-10
Limitations on Inspection
ADCI-C9-76
NADCA-C9-88
NADCA C-8-1
Checklist for Die Casting

Production Part Purchasing
ADCI-C10-76
NADCA-C10-88
NADCA C-8-2
Checklist for Finished Die Cast

Production Part Purchasing
ADCI-Q1
NADCA-Q1
Quality Assurance
pgs. 7-9
Drawing & Specifications
ADCI-Q2
NADCA-Q2
Quality Assurance
pgs. 7-10
Gage, Measurements & Test Equipment
ADCI-Q3
NADCA-Q3
Quality Assurance
pgs. 7-11
Statistical Quality Control
Certified Zinc Alloy Plan for Die Casting
G u i d e l i n e & C h ec k l is t
C r oss Re f e r e nc e
Cross Reference between former ADCI Product Standards, former NADCA Volume 401 Product
Guidelines and NADCA 2015 Product Specification Standards for Die Casting.
vi
ADCI
NADCA #401
NADCA 2015
Subject
ADCI-Q4
NADCA-Q4
Quality Assurance
pg. 7-10
FAIR
ADCI-Q5
NADCA-Q5
Quality Assurance
pgs.7-12
Porosity
ADCI-Q6
NADCA-Q6
Quality Assurance
pg. 7-17
Pressure Tight Castings
ADCI-E1-83
NADCA-E1-83
NADCA-E1-65
NADCA S-4A-1
NADCA P-4A-1
Linear Dimension Tolerances
ADCI-E2-83
NADCA-E2-83
NADCA-E2-65
NADCA S-4A-2
NADCA P-4A-2
Parting Line Tolerances
ADCI-E3
NADCA-E3-83
NADCA-E3-65
NADCA S-4A-3
NADCA P-4A-3
Moving Die Component Tolerances
ADCI-E4
NADCA-E4-83
NADCA-E4-55T
NADCA S-4A-7
NADCA P-4A-7
Draft Tolerances
ADCI-E5
NADCA-E5-83
NADCA-E5-65
NADCA S-4A-8
NADCA P-4A-8
Flatness Tolerances
ADCI-E6
NADCA-E6-83
NADCA-E6-65
(1) (See below)
Depth of Cored Holes
ADCI-E7
NADCA-E7-83
NADCA-E7-65
(1) (See below)
Draft Requirements in Cored Holes
ADCI-E8
NADCA-E8-83
NADCA-E8-65
NADCA S-4A-9
NADCA P-4A-9
NADCA P-4A-10
NADCA S-4A-11
Cored Holes for Threads

(1) The Cored Holes for Threads secions
requirements include cored hole & draft
requirements
ADCI-E9
NADCA-E9-83
NADCA-E9-65
NADCA G-6-4
Ejector Pin Marks
ADCI-E10
NADCA-E10-83
NADCA-E10-65
NADCA G-6-5
Flash Removal
ADCI-E11
NADCA-E11-83
NADCA-E11-65
Engrg. & Design

Pg. 5-11
Location Tolerances
ADCI-E12
NADCA-E12-83
NADCA-E12-65
Engrg. & Design

Pg. 5-13
Concentricity Tolerances
ADCI-E13
NADCA-E13-83
NADCA-E13-65
NADCA S/P-4A-13
Machining Stock Allowance
ADCI-E14
NADCA-E14-83
NADCA-E14-65
NADCA S-4A-12
Die Cast Threads
ADCI-E15
NADCA-E15-83
NADCA-E15-65
NADCA G-6-2
NADCA G-6-3
Fillets, Ribs & Corners
ADCI-E16
NADCA-E16-83
NADCA-E16-65
NADCA G-6-7
Lettering & Ornamentation
ADCI-E17
NADCA-E17-83
NADCA-E17-63T
NADCA G-6-1
Pressure Tightness
ADCI-E18
NADCA-E18-83
NADCA-E18-64T
NADCA G-6-6
Surface Finish, As-Cast
ADCI-M1
NADCA-M1
Alloy Data Tables

Pg. 3-42
Alloy Cross Reference Designations
L is t o f N A DC A S t a n d a r ds,
G u i d e l i n es & C h ec k l is t s
Title
NADCA No.
Format
Page
T-2-1-15
T-2-2-15
Checklist
Guideline
2-17
2-19
A-3-1-15
A-3-2-15
A-3-3-15
Standard
Standard
Guideline
3-5
3-6
3-7
A-3-4-15
A-3-5-15
A-3-6-15
Standard
Standard
Guideline
3-13
3-14
3-15
A-3-7-15
A-3-8-15
A-3-9-15
Standard
Standard
Guideline
3-17
3-18
3-19
A-3-10-15
A-3-11-15
A-3-12-15
Standard
Standard
Guideline
3-21
3-22
3-23
A-3-13-15
A-3-14-15
A-3-15-15
Standard
Standard
Guideline
3-27
3-28
3-29
Tooling
New Die Casting Die/Inherited Die Specifications
Guideline to Increase Die Life
Aluminum Alloys
Chemical Compositions
Properties
Die Casting Characteristics
Aluminum Matrix Composites

Properties
Copper Alloys
Properties
Magnesium Alloys
Properties
Zinc and ZA Alloys

Properties
Coordinate Dimensioning
Angularity
Concentricity
Parting Line Shift
Draft Tolerances
Draft Tolerances
Flatness Tolerances
Flatness Tolerances
S-4A-1-15
P-4A-1-15
S-4A-2-15
P-4A-2-15
S-4A-3-15
P-4A-3-15
S/P-4A-4-15
S-4A-5-15
S-4A-6-15
S-4A-7-15
P-4A-7-15
S-4A-8-15
P-4A-8-15
Standard
Precision
Standard
Precision
Standard
Precision
Standard/Precision
Standard
Standard
Standard
Precision
Standard
Precision
4A-7
4A-8
4A-9
4A-10
4A-11
4A-12
4A-13
4A-17
4A-19
4A-21
4A-23
4A-29
4A-30
Cored Holes for Cut Threads Tolerances

Cored Holes for Cut Threads Tolerances
Cored Holes for Formed Threads Tolerances
Cored Holes for Pipe Threads Tolerances
Cast Threads
S-4A-9-15
P-4A-9-15
P-4A-10-15
S-4A-11-15
S-4A-12-15
S/P-4A-13-15
Standard
Precision
Precision
Standard
Standard
Standard/Precision
4A-34
4A-35
4A-36
4A-38
4A-39
4A-40
S-4B-1-15
Standard
4B-3
G-6-1-15
G-6-2-15
G-6-3-15
G-6-4-15
G-6-5-15
G-6-6-15
G-6-7-15
Guideline
Guideline
Guideline
Guideline
Guideline
Guideline
Guideline
6-3
6-4
6-5
6-6
6-7
6-8
6-10
C-8-1-15
C-8-2-15
Checklist
Checklist
8-14
8-15
Engineering & Design: Miniature Die Castings

Tolerances
Additional Specification Guidelines

Pressure Tightness
Fillets
Ribs & Corners
Ejector Pins, Pin Marks & Pin Flash
Casting Flash Removal
Surface Finish, As Cast
Die Cast Lettering & Ornamentation
Specification Checklists
Die Cast Production Specifications
Die Cast Surface Finishing Specifications
vii
Current Revisions and Additions

Title
Page
Comment
Die Casting Die Specification

Checklist
2-17
Checklist updated to allow specific alloy to be written in
Guidelines to Increase Die Life
2-19
Guidelines 8 and 9 added
Alloy Data
3-11
Tables 7 and 8 added for chemical composition and

properties of suggested and company specific alloys
Zinc Alloy Properties at

Temperature
3-37
Alloy 2 added
More data points and modulus added for other alloys
Aluminum Alloy Data
3-42 & 3-43
EN specifications and chemical composition added for

aluminum alloys
Zinc Alloy Data
3-45
Expanded zinc cross reference specifications and added

chemical compositions
Parting Line
4A-9 to 4A-12
Clarified terminology for calculating parting line tolerance

and parting line shift tolerance
Miniature Die Casting Dies
4B-6
M-2 and H-13 added as die material options in table
Primary, Secondary, and

Tertiary Features & Datums
5-4
Rewritten to explain more clearly
Material Conditions
5-8 & 5-9
Rewritten to explain more clearly
Ribs and Corners in Die Cast

Parts
6-5
Section on Small Metal Savers added
Ejector Pins, Pin Marks and Pin

Flash
6-6
Section on Bumping Ejector Pins added
JIT Delivery
8-9 & 8-10
Just In Time Delivery section removed
Compliance with Laws
8-11
Section on Compliance with Laws added
Intellectual Property
8-13
Section on Intellectual Property added
Edits Made Throughout New photographs and revised line drawings added throughout
viii
Process and Material Selection

for Product Recyclability
Frequently Asked Questions (FAQ)
1) A
re die cast materials recyclable?
See page 1-4, Die Castings Unique Environmental Position, Figure 1-1, and page 1-5,
Die Castings Recycling Circle.
section
2) I s there some comparison between recycled aluminum and virgin aluminum?

See page 1-4, Comparison of Recycled vs. Virgin Aluminum Chart.
3) How do die castings affect the environment?
See page 1-4, Die Castings Unique Environmental Position.
4) A re die castings more readily recyclable than plastics or other non-metallic components?
See page 1-3, Problems Confronting Non-Metallic Recycling.
Introduction
Designers today are faced with material selection considerations that an earlier generation of
engineers did not consider.
In addition to optimizing the cost and performance equation of a new or redesigned product,
engineering must now more carefully analyze its long-term environmental impact.
An increasing population has available to it a decreasing number of waste disposal sites, with
nearly 70% of landfill capacity predicted to be exhausted by the end of the decade. There has
been a vast growth in the use of raw materials not readily recyclable. These forces have led to
heightened government concern with the environmentally safe disposal of durable goods waste.
Die casting alloys offer the designer concerned with post-consumer recyclability one of the
most advantageous material options. Die castings and the die casting process provide the product
engineer who is designing for the environment:
Components that can maintain their integrity through disassembly, repair,
remanufacturing and reassembly.
Product recyclability, at the end of useful life, with the potential for return
to high performance applications.
Knowledge that a proven recycling infrastructure is in place to reclaim recycled die cast parts.
Here is an overview of current North American environmental concerns, the manufacturing

process and material alternatives that offer creative solutions for todays product designer.
New Design Responsibilities
Most engineers, as concerned citizens of their society, know that the problems of waste disposal
are serious. The U. S. Environmental Protection Agency has estimated that we have reached the
point where nearly half of the solid-waste landfills in the United States have been closed.
Disappearing waste disposal sites are an even more serious problem in Europe, where the
cost of waste disposal in landfills or by burning has increased dramatically. In Germany, with
limited availability of waste sites, the government has introduced a bill to attack the problem
of automobile disposal, requiring carmakers to take back old vehicles at no charge to the
consumer. Legislation there now bans incineration.
Minimum-content laws have been passed by many U.S. states, mandating the use of recycled materials in new products. Washington has issued an executive order requiring government agencies to give
preference to recycled materials when purchasing products. Waste disposal alternatives such as incineration and ocean dumping will no longer be acceptable, with government regulations calling on product
manufacturers to insure the minimal environmental impact of their manufactured durable goods.
It appears clear that the product designer will soon not only be responsible for the optimum
function and easy fabrication of a product, but will also be required to account for the products
ultimate destiny at the end of its service life.
1-1

2
Implications of the Emerging Green Consensus
c
Figure 1-1 Circle of recycling to create a die casting. Recycled cans are
collected (a), cans are remelted with other aluminum scrap (b) to create
ingots (c), ingots are used to create a die casting (center).
Images Courtesy of Norsk Hydro, Alcoa, NADCA.
The need for manufacturers to focus on ecological consequences has been stated not only by business management scholars from institutions like Northwesterns Kellogg School of Management
and the University of Michigan, but by business leaders as well. Companies like AT&T, NCR,
Whirlpool Corp., DEC, and Northern Telecom have publicly addressed the issue.
The obvious conflict between business and environmental interests is being altered by a trend
toward business greening encouraged by a new awareness among consumers. American consumer surveys have shown that 80% of Americans said they would pay more for environmentally
safer products. Based on actions that follow from such findings, designing for the environment
appears here to stay. The recyclability of a car model or other durable goods may soon become a
competitive feature in a consumers purchasing decision.
Increasing numbers of people are asking more sophisticated questions about products and the environment, such as concerns over the life cycle of the products they use and the potential for recycling.
Companies which address environmental concerns in the design of their products will be at a
long-term competitive advantage. Among other guidelines, an orientation involves (1) the minimum use
of virgin materials and non-renewable forms of energy, and (2) minimizing the environmental cost of
products and services over their entire life cycles, from their creation to disposal or completion.
There are four steps in adopting a strategy for environmental excellence in manufacturing to be
competitive in the 21st century:
1-2

C
onducting an environmental vulnerability assessment of processes and products.
Conducting a life-cycle assessment for each product and process.
Designing and developing green products for existing and new markets.
Moving toward zero-waste manufacturing processes.
The Designers Material Choices
A product engineer designing products for environmental compatibility encounters many material
suppliers who claim that their materials and processes offer recyclability. Other considerations
being equal, what the designer of todays products must distinguish between are theoretical or
future possibilities of reprocessing a material, on the one hand, and in-place recycling, on the other.
The facts are that metals can claim the support of an existing world-wide infrastructure that
economically collects, reprocesses and channels these reprocessed materials back into the manufacturing process to allow reuse at costs significantly less than purchasing virgin materials.
Supporting the automotive industry, a network of automotive dismantlers daily make their
living selling salvaged metal auto parts and then placing the remainder of the vehicle in the
hands of shredders. The shredding process, which has proven its economic viability, results
in the recycling of almost 75% of the weight of a typical car nearly all of this as ferrous and
nonferrous metal. Over 85% of the aluminum in a car is currently reclaimed and recycled.
The non-metallic portion of a product is generally regarded by recyclers as fluff, consisting
mostly of plastic. Nearly one-quarter of all solid waste is estimated to be plastics, and less than
3% of this plastic is being recycled.
Problems with plastic product recyclability were pointed out by a national task force in 1994
who requested that plastics marketers refrain from use of the universal symbol for recycling in
advertisements, since it was regarded as misleading in relation to plastics.
The greater proportion of non-metallics in a product, the less its value to the recycling industry, and, increasingly, there are fewer and fewer places for disposal of this material.
Problems Confronting Non-metallic Recycling
While most plastics are capable of being recycled, the infrastructure for such recycling is
far from being in place. While many early recycling efforts among consumers have met with
cooperation, end results to date have not been promising.
4.1
Reprocessing Gap
With some exceptions in the case of plastic bottles and foam containers, the monetary incentive and
basic infrastructure either to handle collected plastics and to reprocess it economically is lacking.
Also, there is no substantial market for most of the durable plastic scrap. Existing recycling
organizations continue to regard most plastics as they always have, as non-metallic material
with little established value, that must be separated out from profitable, reclaimable metal. For
even the lower level of plastics applications, virgin resins remain significantly lower in cost than
recycled plastics.
4.2
Separating Plastic
The plastics industry recognizes that it will be some time before a working infrastructure for plastics
recycling and reprocessing is in place, particularly for injection-molded resins. The introduction of
plastic composites, to approach the strength of cast metal, has caused still further recycling problems.
In Europe there has been action to subject reinforced engineering plastics to additional
taxation, based on their incompatibility in the eventual recycling stream. While incineration
has been curbed for reasons of air pollution, heat and flame-resistant plastics might further limit
such disposal as an economic alternative.
1-3

The incompatibility problem in reclamation also occurs with the wide variety of non-reinforced
engineering resins in use, as well as with plastic product combinations which join the properties
of several plastic resins in a single product. Unlike plastics, a combination of several aluminum
alloys made from different processes can be directly recycled. A component produced as a
combination aluminum die casting and aluminum extrusion can readily be remelted and reprocessed as the two have been, separately, since nonferrous alloy recycling began.
4.3
Plastic Degradation
Studies by the plastics industry have indicated that, even with a plastics recycling infrastructure
in place, the use of recycled engineering plastics can yield unpredictable results.
Unlike recycled metals, the effects of temperature, time and the environment can degrade the
potential performance of a recycled engineering thermoplastic, aside from the obvious effect on
the aesthetics of the final product molded from recycled material. While post-consumer recycled
resins are already being molded for low appearance uses, unpredictable performance degradation
may render such material unusable for stricter engineering applications.
As an alternative to injection-molded engineering thermoplastics, recyclable die cast metals
offer the product designer the opportunity to respecify product components as precision die
castings, often with newly realized cost savings and strength and performance advantages.
Comparison of Recycled vs. Virgin Aluminum

Energy
Savings
95% Energy savings; recycling of one aluminum can saves enough energy to run a Television for three hours.
Environmental
Impact
Reduces pollution by 95%.
Natural Resource
Savings
4 lbs. of bauxite saved for every pound of aluminum recycled.
Miscellaneous
Information
Enough aluminum is thrown away to rebuild our commercial air fleet four times every year
Die Castings Unique Environmental Position
Nearly all metals and die castings in particular have always been readily recyclable. Die castings
are not hazardous waste and pose no problems in handling or reprocessing, as do some non-metallics.
Die castings offer the product designer recyclable components with engineering advantages
not available in other metalforming processes. The major cost and performance benefits of parts
consolidation possible with plastic components can be carried forward in die casting designs with
additional advantages.
Net-shape die castings can be produced with thinner walls than comparable plastic parts, and can
provide greater strength and product durability over a longer life cycle with added serviceability.
Cost-effective die cast components can survive higher temperatures and user abuse, compared
to plastic counterparts.
Threaded inserts and EMI/RFI shielding, additionally required for many plastic electronic
housings, can be eliminated with a die cast housing, resulting in lower unit costs. Metal inserts
in plastic housings serve to further complicate plastic recycling.
Parts redesigned as a single die cast unit from a combination of metal and plastic components,
or from components produced in a variety of metals, can not only result in significantly lower
costs and improved performance, but also yield advantages for recyclability. Many examples exist
over a wide range of die cast product applications.
1-4

The housing frame for a tabletop bundling machine for applying plastic strapping was redesigned as
a near net-shape die casting, replacing 27 separate components consisting of stampings and heavily
machined parts.
A die cast feed horn wave guide for a satellite receiving system was produced as a single net-shape
part, as opposed to multiple components requiring several manufacturing processes.
The die cast design for a passenger car gearshift selector tube, part of a passive restraint steering
column, replaced a steel shaft and multiple-piece assembly at a savings of over $1.00 per part, for a
$3 million annual cost reduction.
A multiport valve body for a tractor-trailer spring brake release valve became a single die casting, to
replace a multiple assembly of fittings with significantly reduced machining costs.
An office machine bracket, redesigned as a single die casting, originally consisted of eight metal components, each produced from six different alloys and processes.
A trimmer-mower housing die casting has enabled a number of significant advantages, such as steerable wheels and a sleek design, setting it apart from competitors who utilize stampings. Housings
fabricated from stampings contain more parts and are not lower in cost.
A die cast lower crank case for a motorcycle was designed to eliminate costly secondary machining
operations and additional engine parts.
A bracket for an electronic enclosure was converted from a machined part to a die casting. The die
casting is cast to net-shape and eliminates all machining.
A die cast modem frame was designed to replace an assembly. The assembly was a plastic part sandwiched between two metal plates and held together with self-tapping screws. The one-piece die casting
results in cost savings to the customer.
A die cast head node for a mountain bike was converted from investment cast parts, to a unique
design, yielding a 30% weight savings, part and assembly cost savings, better consistency in impact
and fatigue and better performance.
5.1
Eliminating Waste through Increasing Product Life
Since scrap avoidance is one of the most effective ways to reduce waste, a new design emphasis is
being placed on increased product life.
A designer should weigh the snap-fit capability of molded plastic against the ability to disassemble and reassemble high-strength die cast components, with product integrity maintained
over their useful life. The proven ability of a die cast product to be serviced and/or rebuilt can
result in a doubling of its total life cycle. Aluminum die cast brake housing bodies on heavy
trucks, for example, can be remanufactured after 750,000 miles of service and reinstalled to
perform for an additional 750,000 miles.
Die Castings Recycling Circle
Aluminum die casting alloy recycling has been in place almost from the beginning of custom die
casting production. Today newspaper advertisements for aluminum scrap, such as the one shown
here, are not uncommon.
Specifications for aluminum alloys have been developed that provide for a full range of compositions that can utilize recycled metal. A wide variety of aluminum scrap can be reprocessed to
produce all of the most widely specified die casting alloys.
Over 95% of the aluminum die castings produced in North America are made of post-consumer
recycled aluminum. Since the production of recycled aluminum alloy requires approximately 5% as
much energy as primary aluminum production, there is a dramatic conservation of non-renewable
energy resources.
Die castings, as opposed to forgings or extrusions, for example, can make far greater use of
recycled material.
1-5

The typical life cycle for die cast components is shown in Fig. 1-2. While the recycling circle
for aluminum, copper, magnesium and zinc die cast parts is very similar, each will differ in the
extent to which internally reclaimed alloy at the die casting plant will be reused directly or will
move to a secondary smelter or primary producer for remelting and reprocessing.
When a die cast product is reclaimed at the end of its useful life, it enters the nonferrous alloy
reclamation stream. Nonferrous alloy parts can be readily separated from ferrous components by
long-established magnetic means.
Large assemblies with a high proportion of metal parts, such as automotive vehicles, are the
easiest scrap to be recycled and a well-established infrastructure exists.
High-value components are usually dismantled from vehicles and enter the used parts or
remanufactured parts distribution channel. The remaining automobiles are then shredded, with
75% of the weight of a typical car yielding recycled material, virtually all metal. An average vehicle
in 1998 produced over 168 lbs of aluminum alone for recycling. Though aluminum makes about 9%
or slightly more than 300 pounds of todays car, it can add up to 30% of its recyclable value.
Unlike plastic, there is no necessity to segregate various types of aluminum scrap for remelting
and reprocessing. Reclaimed aluminum from siding, trailers, major appliances, and automobiles produced by a variety of metal forming processes in a range of alloy types can be
recovered by the aluminum smelter using selective thermal processing. Carefully engineered and
analytically controlled chemical composition result in precise specification ingot for each of the
commonly used die casting alloys.
As product engineers seek to design their new products for optimum servicing, reuse and
recycling, aluminum, copper, magnesium and zinc die castings are available to meet their needs.
With an infrastructure in place for reclaimed die casting alloys, and a proven ability to capitalize
on parts consolidation principles, die castings can be respecified for a wide variety of parts
originally conceived as molded plastic.
Where lightest weight is an important product criteria, selected die casting alloys can offer
excellent strength-to-weight ratios, with total part weight virtually identical to the plastic
component being replaced. In selecting materials and manufacturing processes which meet
environmental concerns, the product designer should ask these questions:
Does the material allow for efficient and economical maintenance, repair, refurbishing or remanufacturing of the product to extend its life, where this is a design benefit?
Is the material readily recyclable at the end of its useful life?
Can the material be recovered and reused in high performance applications?
Is the necessary infrastructure in place to make recycling of the reclaimed material a practical reality?
1-6

1
SPECIFICATION
SPECIFICATION
ALLOY
ALLOY
INGOT
INGOT
Steel Mill,
Steel Mill,
Others
Others
Dross
Dross
and
Fines
Fines
SECONDARY SMELTER
SMELTER
SECONDARY
AND
AND
PRIMARY PRODUCER
PRODUCER
PRIMARY
Al, Al,
Cu,Cu,
Mg,
Zn
ZnMg,
Reclaim
Reclaim
Other
Other
Nonferrous
Non-ferrous
Reclaim
DIE
CASTER
DIE CASTER
Finished
Finished
Die
Castings
Castings
Internal
Internal
Reclaim
Reclaim
Ferrous
Ferrous
and
and
Nonferrous
Non-ferrous
Reclaim
Reclaim
Plastic
Plastic
and
and other
other
Fluff
"Fluff"
END-PRODUCT
END-PRODUCT
MANUFACTURER
MANUFACTURER
Component
Component
Remanufacture
Remanufacture
and Servicing
and
Servicing
RECLAIM
RECLAIM
SEPARATION
SEPARATION
FOR
FOR
RECYCLING
RECYCLING
End of
of
End
Product
Life
Product
Life
Final
Final
Assembled
Assembled
Products
Products
END
END
USER
USER
Figure 1-2 The Die Casting Recycling Circle The die casting alloy recycling stream, illustrated above, is based on
an existing worldwide metal reclamation infrastructure that has been operative for more than 40 years. This basic
recycling pattern, with variations based on the amount of reclaimed alloy going to secondary and primary producers, applies to the majority of die castings being currently specified.
1-7

1-8

Section Contents
section
NADCA No.
Format
Page
2-2
1 Introduction
2-3
2 Types of Die Casting Dies
2-4
2.1 Prototyping
2-4
2.2 Rapid Tooling Dies
2-4
2.3 Production Dies
2-5
2.4 Unit Dies
2-6
2.5 Trim Dies
2-6
3 Casting Features and Die Considerations
2
2
2-7
3.1 Core Slide Requirements
2-8
3.2 Parting Line: Cover & Ejector Die Halves
2-8
3.3 Ejector Pins
2-9
3.4 Cast-in Inserts
2-9
4 Die Materials
2-10
4.1 Die and Cavity Materials
2-10
4.2 Die Cavity Insert Materials
2-10
4.3 Die Steel Heat Treatment
2-11
5 Controlling Die Performance
2-11
5.1 Porosity Control: Gating, Venting, Vacuum
2-11
5.2 Thermal Balancing
2-12
5.3 Oil Heating Lines
2-12
5.4 Alternate Surface Textures
2-12
5.5 Extended Die Life
2-12
6 Secondary Machining Preplanning
2-14
7 Gaging Considerations
2-14
8 Inherited Tooling
2-15
9 Engineering Consultation
2-15
10 Database Guidelines
2-16
11 New Die/Inherited Die Specifications
2-16
12 Die Life
2-16
13 Checklist for Die Casting Die Specifications
T-2-1-12
Checklist
2-17
14 Guidelines to Increase Die Life
T-2-2-12
Guideline
2-19
2-1

A-PARTING LINE
Surface where two die halves
come together.
B-LEADER/GUIDE
PIN & BUSHING
Guides the two die halves
together and maintains die
alignment.
C-DIE CAVITY
Die recess in which casting is
formed.
D-STATIONARY &
MOVING CAVITY INSERT
Premium grade tool steel
containing the cavity details.
E-RUNNER & GATES
Precisely designed passage
thru which metal flows from
sprue hole or cold chamber
into die cavity.

1) W
hat type of material should be used for die cavity inserts?
See page 2-10, Die Materials
2) W hat is the proper heat treatment procedure for dies?
See page 2-11, Die Steel Heat Treatment
3) W hat is the difference between a Prototype Die and a Rapid Tooled Die?
See pages 2-4, Prototype Dies and 2-5, Rapid Tooled Dies.
4) W hy are trim dies used?
See page 2-6, Trim Dies.
5) W
hat is the difference between a unit die and a self-contained die?
See pages 2-3 through 2-6, Types of Die Casting Dies.
6) W hat types of venting air are possible on a die?
See page 2-11.
F-COLD CHAMBER
Passage thru which metal
enters runners and gates.
LEADER/GUIDE PIN BUSHING
LEADER/GUIDE PIN
PARTING LINE
COOLING LINE
F1-SPRUE HOLE
& SPRUE PIN
Forms passage thru which
metal enters runners & gates
in a hot chamber die.
G-CORE
Usually a round tapered pin
used to cast various hole
details.
H-STATIONARY/COVER
MOLDBASE
Stationary holder that
contains and supports the
cover inserts.
DIE CAVITY
RUNNER
& GATE
K-MOVING/EJECTOR
MOLDBASE
Movable holder that contains
and supports the ejector
inserts.
L-RAILS
Supports the ejector side
moldbase and contains
clamp slots.
M-RETAINER AND
EJECTOR PLATE
Contains and pushes the
ejector pins.
N-SUPPORT POST/PILLAR
Additional support members
to resist die deflection.
O-GUIDED EJECTION ASSEMBLY
(STOP, PIN & BUSHING)
Supports and guides the
ejection system.
P-CLAMPING SLOTS
Opening for die clamps to
mount die halves to machine
platens.
2-2
GUIDED EJECTION
ASSEMBLY
STOP
PIN
BUSHING
COLD
CHAMBER
I-RETURN PIN
Large ejector pin that resets
ejection system.
J-EJECTOR PIN
Pin which pushes casting from
die cavity.
RAIL
STATIONARY &
MOVING CAVITY
INSERTS
E
F
CLAMPING SLOTS
RETAINER AND
EJECTOR PLATE
SUPPORT
POST/PILLAR
CORE
STATIONARY/COVER
MOLDBASE
RETURN PIN
MOVING/EJECTOR
MOLDBASE
EJECTOR PIN
RAIL
COLD CHAMBER DIE

E
Figure 2-1 Shown above is a multiple-cavity cold
chamber die casting die. With this process the metal
enters the die runners, gates and cavity through the cold
chamber. The Sprue replaces the cold chamber in the
hot chamber process which is used for zinc and smaller
magnesium components.
RUNNER
& GATE
F1 SPRUE
HOLE
&
SPRUE
PIN
HOT CHAMBER DIE

1 Introduction
The die casting die, or mold, is a closed vessel into which molten metal is injected under high
pressure and temperature, then rapidly cooled until the solidified part is sufficiently rigid to
permit ejection from the mold.
For longevity of operation in this environment the die casting die must be built from high-quality tool
steel, heat-treated to the required hardness and structure, with dimensions of the die and cavity machined
to exacting specifications. The two die halves run in a die casting machine that is operated at the required
temperatures and pressures to produce a quality part to net-shape or near-net-shape customer specifications.
The customers product design requirements directly affect the size, type, features, and cost of
the required tooling. The items involved in the tooling decision include the number of cavities,
number of core or slide requirements, weight of the die, machining, finish requirements, polishing
and plating to name just a few. A convenient checklist of die construction considerations, intended
for use in discussion with your custom die caster, appears at the end of this section (page 2-17).
Explanation of the most important terms related to die design are given in the following sections of this chapter. A complete glossary of die casting terms appears at the end of this volume.
The discussion in this section provides a guide to aid the die casting specifier in understanding
the requirements of the die caster that will be necessary to produce the optimum die casting, by
the most economical production methods.
The various alloys available for die casting, from aluminum to zinc, require unique and special
features in the die that produces them. Because of these differences, the descriptions and parameters described in this text are generic. Where possible, options are listed but should be used only
as a general guide, with the final decisions discussed between the customer and the die caster.
Figure 2-2 A unit die casting die, like the one above, allows use of replaceable cavities in standardized main die
frames for lower die costs.
2-3

2
Types of Die Casting Dies
There are various types of die casting dies and each serves a critical need for the customer. The
choice of which type of die casting die the customer requires is usually determined by the following:
Size of the part to be cast
Volume of parts required
Requirements for family sets of parts
Desirability of core slides
Requirements for cast-in inserts.
Figure 2-3 This single cavity die uses the moveable die components (slides) to produce complex features in
the part shown.
2.1 Prototyping
Prototypes are usually requested by the customer to produce a small number of castings under
production conditions. They enable thorough product testing and market exposure before committing to full production dies.
Only production from an actual die casting die can yield a part with precise die cast characteristics. However, there is a range of prototyping strategies that can be employed to approximate
a die cast part for eventual production die casting. Among them: gravity casting, including the
plaster mold process; machining from previously die cast parts or from wrought and sheet stock;
and rapid prototyping techniques such as stereolithography (See the NADCA design manual,
Product Design for Die Casting.)
2.2
Rapid Tooled Dies
Rapid tooling is a term that refers to dies and inserts produced by methods shorter in lead-time
than the conventional method of rough machining, heat treating, and finish machining. Rapid
tooling methods include processes such as LENS (Laser Engineered Net Shaping), EBM (Electron Beam Melting), RSP (Rapid Solidification Process), SLS (Selective Laser Sintering), DMD
(Direct Metal Deposition), and high speed machining of unhardened steel or pre-hardened tool
steel. Investment casting, and KTEL may also be used. Tools produced by these methods may
be utilized as prototype or production dies. Production volume requirements may dictate which
rapid tooling methods are most viable.
2-4

2.3
Production Dies
These are the most common types of tools produced. They range from a single-cavity die, with
no slides, to a mulitple-cavity die with any number of slides. The cavities are made from highquality tool steel, retained in a quality holder block.
Production dies are built to critical dimensions, coring the maximum amount of stock from
the casting, and allowing the agreed-upon amount of machining. A unit die is a special type of
production die.
Die Caster
Owned
Unit Holder
Cavity Block
Customer Owned
or
Replaceable
Cavity Unit`
Cavity
Insert
Figure 2-4 Components of a unit die illustrate each part of the assembly and the die construction option of a cavity
block or a holder block with cavity insert.
Single-Cavity Die
Multiple-Cavity Die
2-5
Family Die
2.4
Unit Dies
A unit die is a lower cost production tool that has a standardized main die frame and replaceable
cavity units. These replaceable units are designed to be removed from the main die frame without
removing the standard frame from the die casting machine.
The most common commercial types of unit dies are single and double unit holders. These
types of dies are generally used for smaller parts, or a family of parts, with no slides or a minimum number of slides. Unit dies limit the use of core slides because of the configuration needed
for interchangeable unit inserts and the limited space available.
Figure 2-5 Photo on left shows untrimmed zinc die casting as it comes from the die. At right, the same casting
after trimming.
2.5
Trim Dies
The trim die is a tool that trims the runner, overflows, and flash from the casting. The trim dies
are single or multiple cavity tools, made in the same configuration as the die casting die.
Depending on the shape of the casting, the trim die may be a simple open-and-close trim die
or it may include as many slides as the die casting tool. In some cases multiple station trim dies
will be used for successive trimming operations.
Trim dies require as much attention to detail in design as the die casting tools and the use of
quality materials should be specified to extend their productive life.
2-6
Figure 2-6 Most cracking can be eliminated with larger radii.
Casting Features and Die Considerations
The features that are required of a cast part determine the complexity of the die. The simpler the
part, the lower the cost of the die casting tool.
The customer should look at the casting in terms of total manufacturing cost. The die caster
will aid the customer in examining not only the part designs castability, but also all of the
secondary operations that may be required.
Castability and die cost will be determined by answers to the following: Are the wall thicknesses as well as the ribs constant, or do they vary greatly? If bosses exist, do they vary widely in
diameter? Will any thin channels on the design create thin standing slivers of steel on the die? Is
the part number and other engraving recessed into, rather than raised out of, the casting, making
the die more difficult to machine? Are the cored holes that may be called for extremely small
in diameter and thus difficult to cast? Is the part designed with sharp corners, promoting stress
cracks or with generous radii? See the figure 2-6 and fillet information on page 6-4.
Figure 2-7 This ejector die half shows the two moveable cone-shaped core slides, A, at left which form the
interior of the die castings in this two-cavity die. Opposite slides are at the right.
2-7

For the proper design of production tooling, pressure tightness, secondary machining and
surface finishing specifications must be understood in detail. Areas of the casting subject to
machining must be fully discussed at the outset, so that the die can be designed to reduce to an
absolute minimum the presence of porosity in those areas. Cosmetic surface requirements for the
casting will require specific steps in finishing the cavities of the die.
These are among the types of questions that the customer should be prepared to discuss with
the die caster while reviewing the supplementary checklist at the end of this section.
The Engineering and Design sections provide detailed treatment of the tolerancing implications of
various casting design features, as well as guidelines which apply under differing casting conditions.
3.1
Core Slide Requirements
Fixed cores and core slides (or pulls) can be designed in the die to cast selected features in place,
eliminating the need for most or all secondary machining of the cast part.
Core slides, similar to collet or cam movements, can be activated by various sources of motion.
Two of the most common are angle pins and hydraulic cylinders.
The angle pin is a mechanical source of motion that is activated by the die opening and closing.
Its advantages are that it does not require hydraulics or limit switches, and is generally more
economical to manufacture. Its limitations are that it can be used only for short slide travel and
there is no control over the cycle of the slide pull. It is not recommended for use on top slides.
Although the use of springs can make this possible.
The hydraulic method of slide motion permits: a choice of cycles, the placement of slides on the top of
the die, and avoids interference when removing the casting from the die (as is the case with the angle pin).
Among the other methods of motion are rack and pinion, ejector lifter, and cam bars. The choice
of motion depends on factors such as production volume, size of die, length of travel of slide, size of
area being cored out and the configuration of the part. The die caster should be relied upon for the
optimum recommendations on core slides, also called moving die components or moving die parts.
3.2
Parting Line: Cover and Ejector Die Halves
The parting line is that perimeter on the casting which is the separation point of the two halves of the die
casting die. This line affects which half will be the cover die half and which will be the ejector half.
This line also influences any tolerances that must be held in this area of the casting. Tolerancing standards specific to part characteristics at the parting line are presented in Engineering and Design, Section 4A.
Parting
Parting
Line A
"A"
Line
Parting
Parting
Line "B"
Line
B
Figure 2-8 Step parting line A, originally placed on this casting drawing would not
have produced the best production results. The location of the parting line B in the bottom
drawing will allow better casting fill and cleaner casting trim, plus provide longer die life
and a less costly die to build.
2-8
Ejector Die
Die Casting
Figure 2-9 Ejector pins, shown in black, are recessed as the metal fills the die cavity (above left); then actuate
sequentially to release the casting from the die (above, right).
It is not obvious where the parting line on a casting drawing should be placed. Where the
parting line is indicated by the part designer, it is necessary for the die caster to confirm the
designers determination. Agreement on the optimum parting line location is essential for the
casting to be produced to the desired specifications.
In the case of a part that must have a cosmetic surface, the cover half will generally be used to produce
the cosmetic surface. This permits the ejector half to contain the ejector pins, inserts and any engraving.
If there is no cosmetic surface requirement, the casting can be oriented to suit the most
favorable casting conditions. On cosmetic parts, the customer must discuss with the die caster
where the gate, overflows and vents will be, to be certain that there is no interference or
blemish on the important cosmetic surfaces.
Where there are cosmetic requirements, since normal, incremental die erosion is inherent in
the die casting production process, the customer will want to discuss special die maintenance
procedures to extend the ability of the die to produce parts with the required high-quality
surface finish. Secondary operations to the surface of the part, such as polishing or buffing,
should also be discussed to maintain cast part specifications.
3.3
Ejector Pins
Ejector pins are used to push the casting out of the die after the metal shot has been made and
casting solidified. The location and size of the ejector pins are dependent on the configuration,
size, and other requirements of the casting.
The die caster will always attempt to locate ejector pins in a nonfunctional area of the casting, such as
in an overflow, on a boss, in the bottom of a deep pocket, or the bottom of a rib. His recommendations
are important as to the size, location and number of ejector pins required for successful part production.
Each ejector pin must be sized to suit the casting configuration in the selected area and will leave
a slight impression on the cast surface. For this reason, they are not placed against the cosmetic
surface side of the part.
Product standards related to ejector pin locations are discussed in Engineering and Design, Section 6.
3.4
Cast-in Inserts
In some castings, there may be a need for a bearing surface, internal thread, or some other
unique feature that could be accommodated by an insert molded into the casting. This requirement can often be met by the die caster within the normal operation of the casting process.
This insert molding offers the advantage of firmly setting an insert into the casting so that it
can be machined, drilled and tapped. This advantage, however, rarely offsets the added costs of the
insert casting operation.
The added costs result from reduced machine cycle time, due to loading the insert into the die
and the heating procedure required to heat the inserts before they are placed into the die half. This
preheating is recommended to avoid putting moisture into the die, allowing metal to chill around
the insert and causing the insert to loosen.
2-9

Note:
There are many die materials available that vary in
both their chemical compositions and mechanical
properties. Developments
in high speed machining
and Wire EDM have led to
the use of a wide variety of
tool steels based on cavity
complexity and position
as the material relates to
the gate location. Specialty
tool steels have their own
specific properties but, if
used correctly, can increase
tool life by up to a factor
of two or more. It is also
important to note that they
usually are more costly as
noted in section 4.2. This
increased cost can be more
than offset by the increase
in die life achievable so it
is best to consult with the
die caster as to what some
of the options might be for
a given casting design. Specialty tool steels that do not
require heat treat or are preheat treated before machining have been successfully
used in both Prototype and
Rapid Tooled Dies for early
production starts.
Some of the (but not limited
to) manufactures of these
specialty steels are Aubert
& Duval, Bohler, CMW,
Daido, Dunn Specialty
Steel, Elwood Specialty
Steel, Kind, Nippon
Koshuha, Schmolz & Bickenbach, and Uddeholm. It
is best to consult with the
die caster as to what some
of the tool steel options
are for individual casting
designs and die construction.
Die Materials
The grade of tooling materials to be used in the construction of a die casting die should be
specified as high quality, at a minimum, and preferable premium quality. These requirements are
based on the extremely high temperatures and pressures used in die casting production.
Tooling grade requirements will vary depending on the tooling component, the alloy being die cast,
the critical character of the cast part design and the long-term production quantities desired. Every
aspect of the proposed products design and production specifications must be discussed with the die
caster before tooling material can be selected. The following are typical tooling lowest requirements:
4.1
Die and Cavity Materials
Die Casting Dies for Zinc Alloys: P-20, H-11, H13, Premium Grade H13 (Per NADCA No. 229),
Superior Grade H13 (Per NADCA No. 229), or other grades as defined in NADCA No. 229..
The zinc alloys, which cast at the lowest temperature in the nonferrous family, cause the least wear on
their tooling and thus permit the use of non-premium die material, such as P-20, in cases where part
designs are relatively simple. Purchasers are cautioned, however, to be aware of the unwise investment
in non-premium grade tooling for zinc parts if there is any possibility that production quantities may
reach higher levels than originally anticipated. At higher production levels, such tooling may expire
and the cost of replacement dies will far outweigh an original investment in premium material.
Die Castings Dies for Aluminum, Magnesium & ZA Alloys
(Noncritical part designs, low volume): H-10, H-11, H13.
Aluminum, magnesium and ZA die casting dies require high quality tool steel, as above.
If part designs have very critical features or if high production runs are being contemplated,
however, premium grade tooling will always be the wisest investment.
Die Casting Dies for Aluminum, Magnesium, ZA-12 & ZA-27 Alloys
(Critical part designs, higher volume): Premium Grade H13 (Per NADCA No. 229), Superior
Grade H13 (Per NADCA No. 229), or other grades as defined in NADCA No. 229.
For Al, Mg, ZA-12, and ZA-27 die cast parts, H13 Premium or Superior Grade tool steel
is recommended whenever part design features are intricate and specifications tight, and when
production volumes will be high. In such cases, non-premium grade tooling will nearly always
result in costly premature die failure.
Die Casting Dies for Brass Alloys: H13
Since copper alloy die castings are cast at the highest temperatures of the nonferrous alloys,
only H13 high grade tool steel is recommended for brass die casting dies.
Metal certifications for the material grades listed, provided by quality tooling material suppliers,
will be made available for inspection by the die caster. The H13 Premium or Superior Grade should
meet the NADCA No. 229 tool steel standard (Special Quality Die Steel and Heat Treatment
Acceptance Criteria for Die Casting Dies).
4.2
Die Cavity Insert Materials
The materials recommended for use as tool steel for die cavity inserts parallel the recommendations for die cavities, above, with some additions.
In addition to H13 Premium or Superior Grade, the maraging and speciality tool steels* are
used for die inserts needing higher hardness to improve their resistance to the heat checking
(thermal fatigue cracking) or crazing of the inserts surface caused by thermal cycling of the
die from the high temperature molten alloy and die spray/die cooling. The fine cracks that may
result can produce corresponding veins on castings.
In high wear (erosion/washout) and temperature areas, especially if internal cooling and/or die
spray is difficult, small cores and inserts in aluminum die casting dies can eventually break or
wash away due to the velocity of the aluminum entering the cavity. Tungsten- and molybdenumbased alloys are occasionally used successfully in these areas to resist these conditions. Although
these materials show superior physical properties compared to conventional steels at high
working temperatures, care must be used in machining them. Also, their increased cost must be
considered in the overall cost of the die and number of shots required (life of the die).
2-10

4.3
Die Steel Heat Treatment
The quality of the heat treatment of the die steel is a very critical step in the tool building process. The
use of high quality rapid quenching heat treatment procedures is essential to normal die life. Care
must be exercised in the heat treatment procedure to balance the issues of distortion with metallurgial
properties that result from rapid quenching. The recommendations of the die caster should be respected.
Just as tool steel source certifications are made available by the die caster, so are the heat treat
certifications from the selected heat treatment sources. This documentation will certify that the
heat treat was properly carried out to achieve the correct hardness and microstructure.
Tool steel heat treatment should be expected to follow NADCA No. 229 heat treatment guidelines
(Recommended Procedures for H13 Tool Steel) and the recommendations of the tool steel manufacturer.
5
5.1
Controlling Die Performance

Porosity Control: Gating, Venting and Vacuum
Although die castings can be expected to exhibit high strength and integrity, some product requirements can call for additional steps in the part design, die design and on-line production stages.
Designers seeking to avoid porosity concerns will be alert to such techniques as eliminating
thick wall sections in their designs. (See Product Design for Die Casting for general guidelines).
For specific designs, the engineer should always consult with an experienced die caster before
design parameters are locked in.
Given the final part design, the die caster will follow specified die design guidelines, and
flow simulation (if available), incorporating die gating, overflow and venting configurations to
evacuate air properly from the die cavity and reduce porosity to an acceptable level. Where pressure tightness is not a casting specification, the process can be designed so that residual porosity
enters only non-functional, internal areas of the casting. Porosity is acceptable in non-critical areas.
While not a substitute for sound product and die design, a vacuum system can also be used to
enhance die fill, reduce gas porosity, and improve mechanical properties. A vacuum system is
designed to evacuate ambient air from within the die cavity during casting and create a negative
pressure or a vacuum. The die must be specially built to accept a vacuum system, so discussions
of acceptable porosity levels should be held well in advance of die design.
Conventional
Vent
Vacuum
Valve
Figure 2-10 Conventional venting in a die casting die, shown at left, vents air to the atmosphere. With
a vacuum-equipped die, metal is pulled into a closed system, with air drawn by the vacuum mechanism.
A significant reduction in air entrapped in the casting results in lower porosity.
2-11

5.2
Thermal Balancing
To achieve maximum product quality, the dies are required to run at a precise, specified temperature. This temperature will vary with such factors as the size of the casting, number of die
cavities, alloy being cast and machine cycle time.
The alloy is injected into the die at this exact temperature at high speeds and then rapidly
cooled for ejection. This extremely fast and repeated cooling requires careful engineering of a
complex network of internal die temperature lines. Infrared imaging and thermocouples placed
in the die can help measure and maintain correct die temperatures.
Proper thermal balancing through the strategic placement of these lines reduces die casting
cycle time, improves casting quality, and lengthens the life of the die.
Different areas of the die can be heated or cooled to different temperatures, i.e., different cover
half and ejector half temperatures can be used to aid control of part density or surface finish.
5.3
Oil Heating Lines
In some cases differential heating of various areas of the die to produce specific casting design
features will be achieved by the use of hot oil lines in the die.
Hot oil systems heat a special oil to a given elevated temperature and pipe it through the die in
the same manner as water cooling lines. Both water cooling and hot oil heating lines may be used.
5.4
Alternate Surface Textures
Using photoengraving techniques in making the die cavities, a wide range of patterns, grainings
and textures can be selected for permanent die casting into the surface of a part. The die caster
can exhibit actual samples of the common die cast textures possible. (For illustrations of sample
textures, see the Surface Treatment chapter of Product Design for Die Castings.)
Figure 2-11 Heat checking as seen on a casting.
5.5
Figure 2-12 Washout as seen on a casting.
Extended Die Life
While optimum die life begins with high quality tool steel, several patented processes are available
which can be used to extend the life of a die casting die. These processes involve shot peening techniques, submersion in special baths, and chemical treatments of the die. The die caster can discuss the
projected effectiveness of such steps to reduce premature die wear in the case of specific part design.
A typical failure mode of dies is heat checking or thermal fatigue cracking.
5.5.1 Heat Checking. Die Casting tools show small cracks (network) as well as bigger (leading)
cracks after some time in use, due to thermal fatigue. Both are important to tool life.
The scale in figure 2-13 is designed to give you a combined grading using both network and
leading crack values.
Compare the scales with your tool. Give the tool a grading from both scales. Add the two
gradings. These two combined readings give you the degree of heat checking.
2-12
Figure 2-13 Photos of die surface crack

patterns reproduced approximately 70% of
actual size. The die steel heat check conditions is reflected as raised material on the
surface of the casting.
Courtesy of UDDEHOLM
2-13

Determine at what point the die will no longer be useful. For critical surfaces, such as those to
be polished or chrome plated, you might stop using the die at a combined rating of six. For other
surfaces, especially those not seen by users of the finished product, the die might be used until
the rating is judged to be greater than 14. As the rating goes up, there is not only an aesthetic
loss but an economic loss in the production of the parts.
The scale also provides a concrete basis of comparison between different tools and number of shots.
Secondary Machining Preplanning
While most die castings are produced to near-net-shape, and many to net-shape, the close
tolerances possible with die casting and the repeatability of the process suits die cast parts to
economical high-precision secondary machining operations.
A die casting can be designed to accurately adapt to machining fixtures by casting in locator
holes or casting a flush locating datum surface. Die castings can be drilled, tapped, reamed,
punched, or have nearly any type of machining operation performed on them.
Machining operations, including gaging and any other secondary operations that may be
required, can be performed by the die caster. Properly designing the part and the die for
optimum quality and economy in secondary machining will have an important impact on
reducing final part costs. Detailed discussions should be held with die caster engineering
personnel to establish such machining parameters as the precise location, extent, and depth of
the machining required; the surface finish required; and any other specification necessary to
result in a quality component.
Decisions on special machining equipment ownership, maintenance and replacement must
also be discussed. Such matters are outlined in the Commercial Practices section of this manual
(page 8-1).
Gaging Considerations
What gages will be used in casting production and in secondary machining, and what they will
check, are important elements of the die casting program.
Gages may be used to check the casting in its as-cast state and again after machining. The gage may
be an attribute gauge, which is basically a go or no-go check and results in either a good or bad part.
A variable gage may also be employed which, used with a computer, can document variables,
collect data, and record Cpks.
More than one gage may be needed to check a casting: one to check it in its as-cast condition
and another to check the casting in a fully machined condition. There may be a need for plug and
thread gages as well as finished gages or standards for painted surfaces.
The gaging should be considered by the customer as part of the tooling package. Gaging
requirements should be resolved early by the quality assurance managers of both the customer
and the die caster, so no questions remain on meeting the part print requirements.
2-14

8
Inherited Tooling
In some instances a customer may transfer a die casting die from one die caster to another.
This generally will raise some operational questions for the receiving die caster of which the
customer should be aware.
The die may need to be put into a different type of die casting machine. This may require some
modifications to the dies ejector system as well as to the shot sleeve, i.e. the entry for molten metal.
The dies gate and runner system may also need to be modified to suit the new machine
conditions. It may be necessary for any residual oil in the hydraulic system of the die to be sent
out for sampling to assure that it does not contain any contaminants.
The die must be evaluated by the customer and the die casters tool room superintendent to
assure that there are no visual problems with the die. They should also determine whether the die
arrived with any required limit switches and hydraulic cylinders.
Upon this review an adaptation cost can be established and agreed upon before the receiving
die caster has invested a large amount of time and expense in preproduction work.
Checklist T-2-1, at the end of this section, will aid in addressing questions regarding transferred or inherited tooling.
Die or tooling ownership and replacement is often a point of discussion. Information regarding this topic can be found in Section 8.
Engineering Consultation
The customer company, in the person of its engineering and quality assurance personnel, will usually be requested to meet with the custom die casters engineering and quality assurance personnel
as early as possible to discuss the design and function of the part design proposed for die casting.
They will discuss the designs function, fit and precise assembly with other components.
The die casting process uniquely lends itself to parts consolidation, decreasing the number of
components in a product assembly.
Early involvement with the die caster is essential in avoiding expensive corrective steps in later die
construction. It can often simplify product assembly and significantly reduce total product costs.
For example, an attached hinge bracket could be die cast as an integral part of the casting. A
slight design modification could assure clearance for a close assembly.
The die caster may be able to cast an integral bearing in the part that the customer was
planning to press in. Or the die caster may be able to perform a complete or partial assembly
operation more economically, such as installing a gasket after painting the casting, and shipping
the part ready for assembly. Many die casters have in-house capabilities for operations such as
pressure testing, impregnating, machining, surface finishing and subassembly.
The experienced die caster should be regarded as a invaluable source of expertise in the die
casting production and assembly process.
Depending on part configuration, very small high-volume zinc parts, weighing fractions of an
ounce, may be recommended for production on special hot-chamber zinc die casting machines.
Such parts, usually called miniature or microminiature die castings, can be cast flash-free,
with zero draft, to very close net-shape tolerances.
2-15

10 Database Guidelines
When databases are utilized, quotations for castings are often based on the assumption that any
CAD databases provided to build tooling and produce parts are complete, usable and are without
need of updating.
Databases may be deemed incomplete and unusable if:
1. The geometry of the part is not physically moldable.
2. The necessary draft and radii are not incorporated.
3. Line and surface geometry are not connected within 0.001.
4. Parting line is not fully developed.
Note: The database file format may not be compatible with existing capabilities and may
require a translator. STL files are usually only used for creation of prototype parts.
Any necessary database manipulation that is caused by incompleteness as described above
could add cost and extended lead-time to tooling.
If databases are designed only to nominal dimensions, tool life and casting tolerances may be
adversely impacted.
If solid model databases are used for tool construction, they should be accompanied by a
limited dimension part print (either paper or database) that contains all tolerancing information
and information pertaining to any secondary machining that is to be performed to the part.
The revision control for databases should be as agreed upon between the die caster and customer.
11 New Die/Inherited Die Specifications

Checklist T-2-1, which follows, will aid in discussions between the customer and the die caster
regarding the important considerations in the design of a new die casting die or in the production of parts from inherited tooling.
12 Die Life
Die casters are frequently asked the question, How many shots will I get from the die before
it needs to be replaced? or How many shots will you guarantee the die for? A better question
might be, What can we do to maximize die life and to minimize replacement costs?
Aluminum and Copper die casting dies wear out due to the aggressive nature and high
melting temperatures of the materials being die cast.
Die life is a consideration of part design, part function, internal part requirements and part
cosmetics. In general, cosmetic areas of the part do not last as long as functional areas.
The following is a suggested approach to be used by the customer and die caster at the time of
part design. The intent is to define critical areas of the die casting before the start of tool design.
This allows areas to be inserted to maximize die life and minimize the replacement costs.
First, is to develop a rating scale by which this information can be used to relate part considerations
to estimated tool life. A guideline (T-2-2) has been developed and includes; a Die Life Checklist,
sample part, example of tool steel inserting and identification matrix starting on page 2-19
2-16

13 Checklist for Die Casting Die Specifications (To be used in consultation with your Die Caster)
T-2-1-15
Part 1 New Die Casting Dies: Items to be Addressed

In the case of new die casting dies, all of the items in Part 1, below, should be reviewed. Note, in
the case of tooling to be transferred to, or inherited by a die caster, the items asterisked (*) in
Part 1 should be addressed, plus the items noted in Part 2 on the next page.
Type of
New Die
Cavity Steel*
Cavity Steel
Heat Treat*
Prototype Die Casting Die

Production Die Casting Die
H13
Premium Grade H13
Superior Grade H13
Other Tool Steel: __________________________________________________
NADCA No. 229 Certification Required: Yes No Grade
Class
Hardness Required:
Toughness Required: ______ ft.-lbs
NADCA No. 229 Certification Required:
Yes
No
Cored Holes*
All Holes Cored

Cored Holes As Noted On Print
No Cored Holes
Die Operation
for Part
Features*
Mechanical Movement
Hydraulic Movement
Features To Be Achieved By Secondary Operations
Estimated
Part Volume
Monthly: _______________________________________________________________
Annual: ________________________________________________________________
Expected Product Life: _________________________________________________
Casting Alloy*
Aluminum
Copper
Magnesium
Zinc
ZA
NADCA
Checklist
This two-part specification
checklist is intended for
use in consultation with
your die caster prior to
estimation of new die
design and construction,
or prior to die casting
production using inherited tooling. It should be
used in combination with
checklists C-8-1 and C-8-2
in Commercial Practices,
Section 8.
Alloy
_____________________
_____________________
_____________________
_____________________
_____________________
_____________________
Casting Weight
Estimated Casting Weight: _____________________________________________
As-cast Part
Finish*
Mechanical Grade (Functional Finish) (Ref. 125 Ra)

Painting Grade (Ref 63 Ra)
Highest Quality (Cosmetic Finish) For Plating, Etc. (Ref. 32 Ra)
Class of Die
Unit Die
Conventional Die
Cast-In Date
Insert*
In Die Cavity
Other Requirements: ______________________________________________
Not Required
Cast-In Part
Number*
In Die Cavity
Other Requirements: ______________________________________________
Not Required
Other
Write in any other special requirements (ie. tolerances, leak testing, x-rays):
____________________________________________________________________________________
*Die wear can affect surface finish over the life of the die.
Single Cavity
Multiple Cavity
Multiple Cavity - Family Die
2-17

NADCA
T-2-1-15
Part 2 New Die Casting Dies: Items to be Addressed (Continued)

Cast-In Logo,
Lettering*
Die Layout
Checklist
This two-part specification
checklist is intended for
use in consultation with
your die caster prior to
estimation of new die
design and construction,
or prior to die casting
production using inherited tooling. It should be
used in combination with
checklists C-8-1 and C-8-2
in Commercial Practices,
Section 8.
First-Piece
Approval
Gages*
Trim Die
Machining
Fixtures
Special Items
In Die Cavity
Other
Include: ________________________________________________________________
Customer Logo
Cavity No.
Supplier Logo
Revision No.
Recycling Logo
Part Number
Customer to Approve Layout
Approval by Die Caster
Customer Approval Before Production Run Required
Run on Die Caster Approval
PPAP
Customer to Supply Special Gages
Die Caster to Supply Special Gages
Mechanical Movement
Hydraulic Movement
Features To Be Achieved By Secondary Operations
No Secondary machining required
Machining reguired, no special fixtures
Special machining fixtures required, customer to supply
Special machining fixtures required, die caster to supply
Special Items to be included in the tooling package:

_________________________________________________________________________
_________________________________________________________________________
Part 3 Inherited Die Casting Dies: Additional Items to be Addressed

In the case of inherited tooling, not the asterisked items (*) in Part 1, plus the items below.
Note that with transferred, or inherited, tooling for die casting production the existing die casting
die, the trim die, and, if required, the secondary machining fixtures, must be available for review and
evaluation to determine whether the dies and fixtures are capable of producing to specifications and the
extent of maintenance and/or rework required before the onset of production. This would include any
adaptations of the die casters equipment to accommodate production using the inherited dies. Final
production estimates will be based on this review.
Inherited Die
Inherited
Trim Die
Inherited
Machining
Fixtures
Die Casting Die Available for Evaluation

Die to be Available for Evaluation (date): __________________________
Trim Die Not Required
Trim Die Available for Evaluation
Trim Die to be Available for Evaluation (date): _____________________
Special Machining Fixtures Not Required
Machining Fixtures Available for Evaluation
Machining Fixtures to be Available for Evaluation (date): __________
Actual Casting
Weight
Weight of Actual Casting: ______________________________________________
Size of Die
Size of Casting Die (for equipment limitations): _________________________
Weight of Die
Weight of Casting Die (for crane limitations): ___________________________
Availability
of Die Design
Yes
No
Publisher grants permission to reproduce this checklist as part of a die casting Request for Quotation or Production Specification.
2-18

14 Guidelines to Increase Die Life
Before the start of tooling
1) Redesign of part to reduce or eliminate sharp internals corners or features that will promote early cracking of the tool steel.
2) Use of special tool steels in areas where high wear is expected (increases
tool costs).
3) Insert areas of cavity blocks for more economical replacement (may
increase tool costs) after tool wear has occurred.
4) Do a surface treatment (shot blasting) to the tool steel to help reduce
heat checking and cracking (adds to tool cost). Note: This will add a
surface texture to the die cast part.
5) Add a vibratory, shot blast or deburring operation to the part to help
extend tool life (added part cost).
6) Add a machining operation to remove heat checking and/or cracking in
areas that are critical on the part (adds to part cost).
7) Reclaim the surface hardness, if possible, when it drops from the 40s
HRC to the high 30s HRC.
8) Coatings can be applied to the die surface to reduce wear and soldering.
9) Use internal cooling instead of die spray to cool the die. Spray is only to
be used as a release agent.
Die Life Checklist

Part
Class Consideration
A
Critical to
Function &
Cosmetic
Cosmetic,
No Function
Critical to
Function
Not Critical
but Functional
No Function
NADCA
T-2-2-15
Guideline
Estimated
Class Die Life/Shots
1
Less than
10,000
10,000 to
25,000
25,000 to
50,000
50,000 to
100,000
More than
100,000
Using the above will

develop and itemize the
areas of concern of a
sample part.
2-19

Sample Part
O-ring Surface
Sharp Corners
Cosmetic
Non-Functional
Functional
Mounting Surface
Non-Functional
Sealing Surface
Using the sample, the next step is to develop an inserting plan for the tool steel construction.
Tool Steel Insert Construction

Insert #
Part Consideration
Estimated Die Life
2 C3
3 E5
Radius
1 B5
6 D4
4 E5
5 C3
7 C3
Last is to develop the matrix for communication of tool steel replacement needs and to develop
history on each insert. (The information shown in this example represents only what can be
done. The actual information to be included should be determined by the customer and the die
caster). Two examples of this type of matrix are shown, at the start of a new project and the other
as it may appear after the first year of production.
2-20
As mentioned earlier this is just a suggested approach to improving die life and reducing replacement costs. Die casting dies do wear out. It is an advantage to both the customer and the die
casters benefit to layout a plan at the start of the project. This allows inserts to be replaced before
any actual failure thus preventing any possible loss of production. The examples shown are only
one of many possible methods to achieve this. If the customer and die caster choose to use this
type of approach, it should be on a part by part basis. The information in the matrix should be
relevant to the actual tool construction and the actual annual usage.
2-21
2-22
Alloy Data
Section Contents
section
NADCA No.
Format
Page
3-2
1 Die Casting Alloy Cross Reference Designations
3-2
2 Aluminum Alloys
3-4
Selecting Aluminum Alloys
3-4
Aluminum Alloy Chemical Composition
A-3-1-15
Standard
3-5
Aluminum Alloy Properties
A-3-2-15
Standard
3-6
Aluminum Alloy Characteristics
A-3-3-15
Guidelines
3-7
3 Aluminum Metal Matrix Composites
3-12
Selecting Aluminum Composites
3-12
Aluminum Composites Chemical Composition
A-3-4-15
Standard
3-13
Aluminum Composites Properties
A-3-5-15
Standard
3-14
Aluminum Composites Characteristics
A-3-6-15
Guidelines
3-15
4 Copper Alloys
3-16
Selecting Copper Alloys
3-16
Copper Alloy Chemical Composition
A-3-7-15
Standard
3-17
Copper Alloy Properties
A-3-8-15
Standard
3-18
Copper Alloy Characteristics
A-3-9-15
Guidelines
3-19
5 Magnesium Alloys
3-20
Selecting Magnesium Alloys
3-20
Magnesium Alloy Chemical Composition
A-3-10-15
Standard
3-21
Magnesium Alloy Properties
A-3-11-15
Standard
3-22
Magnesium Alloy Characteristics
A-3-12-15
Guidelines
3-23
6 Zinc and ZA Alloys
3-26
Selecting Zinc and ZA Alloys
3-26
Zinc and ZA Alloy Chemical Composition
A-3-13-15
Standard
3-27
Zinc and ZA Alloy Properties
A-3-14-15
Standard
3-28
Zinc and ZA Alloy Characteristics
A-3-15-15
Guidelines
3-29
High Fluidity (HF) Properties and Composition
3-30
7 Selecting An Alloy Family
3-32
8 Quick Guide to Alloy Family Selection
3-33
9 Elevated Temperature Properties
3-34
10 Property Comparison
3-38
11 Cross Reference: Alloy Designation and

Composition
3-42
3-1
Alloy Data
The cross reference designations shown are for alloy
specifications according to
widely recognized sources.
References apply to the metal
in the die cast condition
and should not be confused
with similar specifications
for metal ingot. A in
a column indicates that the
specific alloy is not registered by the given source.

1) Is there a cross reference available for different alloy designations?
See pages 3-2, 3-3 all charts and pages 3-42 through 3-45.
2) W hat type of material best fits my application?
See page 3-33, Quick Guide to Alloy Family Selection.
3) How do die cast properties compare to sand cast properties?
See pages 3-38 through 3-41, Property Comparison.
4) W here can I find general material properties for Aluminum Alloys?
See pages 3-4 through 3-11.
5) How can I determine if certain die casting alloys would be a better choice for thermal conductivity? See row Thermal Conductivity in tables found on pages 3-6, 3-14, 3-18, 3-22, 3-28,
and 3-30.
Die Casting Alloy Cross Reference Designations
Aluminum Alloy Specifications

Commercial
360
A360 a
380 c
A380 a
383
ANSI
AA
ASTM
B85
Former
SAE
J452
Federal
QQ-A-591
A03600
360.0
SG100B
b
b
b
B
b
b
b
b
b
b
b
b
A13600
A360.0
SG100A
c A13800 A380.0
SC84A
306
SC114A
303
B390.0
SC174B
A413.0
S12A
518.0
G8A
A03800
A03830
A384.0
A04130
413.0
B390
A23900
A13 a
A14130
UNS Unified
Numbering
System
13
ANSI American
National
Standards
Institute
43
218
SC84B
SC102A
A03840
A384 a
380.0
383.0
384
Table of Symbols
ASTM American
Society for
Testing and
Materials
UNS
A34430
A05180
384.0
C443.0
S12B
S5C
309
308
383
305
304
DIN g
1725
JIS H 5302
233
ADC3
226A e ADC10 CD
226A e ADC12 CD
ADC12 CD
ADC12 CD
231D f
ADC1 c
341
a Similar to preceding entry with slight variations in minor constituents. b The Federal specification for aluminum alloy
AA
Aluminum
Association
SAE
Society of
Automotive
Engineers
die castings uses the Aluminum Association designations for individual alloys. Military designations superseded by Federal
specifications. c NADCA and Japanese specifications allow 0.3 magnesium maximum. d Japanese specifications allow 1.0
zinc maximum. e DIN 1725 spec allows 1.2 max zinc and up to 0.5 max magnesium. f DIN 1725 spec allows 0.3 max
magnesium. g Alloy compositions shown in DIN 1725 tend to be primary based and have low impurity limits making it
difficult to correlate directly to U.S. alloys.
FED
Federal
Specifications
Note: Some of these standards are obsolete but included here for historical purposes. For closest cross-reference refer to the tables of foreign
alloy designations and chemical constituencies at the end of this section. All specifications are for castings only.
MIL
Military
Specifications
JIS
Japanese
Industrial
Standard
DIN
German
Industrial
Standard
3-2
Alloy Data
Aluminum Metal Matrix Composite Alloy Specifications
Rio Tinto Alcan
CANADA
UNS
Copper Alloy Specifications
AA
Commercial
UNS
ASTM B176 SAE J461/
F3D.10S-F
380/SiC/10p
857
C85700
F3D.20S-F
380/SiC/20p
858
C85800
Z30A
J462
F3N.10S-F
360/SiC/10p
865
C86500
F3N.20S-F
360/SiC/20p
878
C87800
ZS144A
J462
997
C99700
997.5
C99750
Magnesium Alloy Specifications

Commercial
UNS
ASTM
B93 & B94
Former
SAE J465B
AZ91B
M11912
AZ91B
501A
AZ81
AZ91D
M11916
AZ91D
AM60A
M10600
AM60A
AM50
AM60B
AE42
AS41A
AS41B
AM20
M10602
AM60B
AS41B
M10410
AS41A
M10412
Federal a
DIN
1729
QQ-M-38 3.5912.05
JIS H 2222
& H 5303
MDI1B
MDI1D
3.5662.05
MDI2A
MDI2B
3.5470.05
MDI3A
a Th is Federal Specification has been canceled and is shown for historic reference only.
Note: For closest cross-reference refer to the tables of foreign alloy designations and chemical constituencies at the end of this section.
Zinc and ZA Alloy Specifications

Commercial
UNS
ASTM
B86
Former
SAE J469
Federal a
QQ-Z-363a
DIN
Z35541
AC43A
921
AC43A
1743
AC41A
1743
Z33520
AG40A
903
AG40A
Z33523
AG40B
AG40B
Z355310
ZA-8
Z35636
ZA-27
Z35841
ZA-12
Z35631
AC41A
925
1743
JIS H 5301
ZDC-2
ZDC-1
a This Federal Specification has been canceled and is shown for historic reference only.
Note: For closest cross-reference refer to the tables of foreign alloy designations and chemical constituencies at the end of this section.
Table of Symbols
UNS Unified
Numbering
System
ANSI American
National
Standards
Institute
ASTM American
Society for
Testing and
Materials
AA
Aluminum
Association
SAE
Society of
Automotive
Engineers
FED
Federal
Specifications
MIL
Military
Specifications
JIS
Japanese
Industrial
Standard
DIN
German
Industrial
Standard
3-3
Alloy Data
2
Aluminum Alloys
Selecting Aluminum Alloys

Aluminum (Al) die casting alloys have a specific gravity of approximately 2.7 g/cc, placing them among
the lightweight structural metals. The majority of die castings produced worldwide are made from
aluminum alloys.
Six major elements constitute the die cast aluminum alloy system: silicon, copper, magnesium, iron,
manganese, and zinc. Each element affects the alloy both independently and interactively.
This aluminum alloy subsection presents guideline tables for chemical composition, typical properties, and die casting, machining and finishing characteristics for 11 aluminum die casting alloys.
This data can be used in combination with design engineering tolerancing guidelines for aluminum
die casting and can be compared with the guidelines for other alloys in this section and in the design
engineering section.
Alloy A380 (ANSI/AA A380.0) is by far the most widely cast of the aluminum die casting alloys,
offering the best combination of material properties and ease of production. It may be specified for
most product applications. Some of the uses of this alloy include electronic and communications
equipment, automotive components, engine brackets, transmission and gear cases, appliances, lawn
mower housings, furniture components, hand and power tools.
Alloy 383 (ANSI/AA 383.0) and alloy 384 (ANSI/AA 384.0) are alternatives to A380 for intricate
components requiring improved die filling characteristics. Alloy 383 offers improved resistance to hot
cracking (strength at elevated temperatures).
Alloy A360 (ANSI/AA A360.0) offers higher corrosion resistance, superior strength at elevated
temperatures, and somewhat better ductility, but is more difficult to cast.
While not in wide use and difficult to cast, alloy 43 (ANSI/AA C443.0) offers the highest ductility
in the aluminum family. It is moderate in corrosion resistance and often can be used in marine grade
applications.
Alloy A13 (ANSI/AA A413.0) offers excellent pressure tightness, making it a good choice for
hydraulic cylinders and pressure vessels. Its casting characteristics make it useful for intricate components.
Alloy B390 (ANSI/AA B390.0) was developed for automotive engine blocks. Its resistance to wear is
excellent but, its ductility is low. It is used for die cast valve bodies and sleeve-less piston housings.
Alloy 218 (ANSI/AA 518.0) provides the best combination of strength, ductility, corrosion resistance and finishing qualities, but it is more difficult to die cast.
* Different sets of properties can be achieved with alternate processes (such as high vacuum, squeeze,
and semi-solid casting) and alternate alloys (such as A356, Aural 2 or 356, and Silafont 36). Information on these processes and alloys can be found in the Product Specification Standards for Die castings
produced by Semi-Solid and Squeeze Cast Processes (NADCA Publication #403) and the High
Integrity Die Castings book (NADCA Publication #404).
Machining Characteristics
Machining characteristics vary somewhat among the commercially available aluminum die casting
alloys, but the entire group is superior to iron, steel and titanium. The rapid solidification rate associated with the die casting process makes die casting alloys somewhat superior to wrought and gravity
cast alloys of similar chemical composition.
Alloy A380 has better than average machining characteristics. Alloy 218, with magnesium the
major alloying element, exhibits among the best machinability. Alloy 390, with the highest silicon
content and free silicon constituent, exhibits the lowest.
Surface Treatment Systems

Surface treatment systems are applied to aluminum die castings to provide a decorative finish, to form
a protective barrier against environmental exposure, and to improve resistance to wear.
Decorative finishes can be applied to aluminum die castings through painting, powder coat finishing, polishing, epoxy finishing, and electro-chemical processing. Aluminum can be plated by applying
an initial immersion zinc coating, followed by conventional copper-nickel-chromium plating procedure
3-4
Alloy Data
NADCA
A-3-1-15
STANDARD
similar to that used for plating zinc metal/alloys.

Protection against environmental corrosion for aluminum die castings is achieved through painting,
anodizing, chromating, and iridite coatings.
Improved wear resistance can be achieved with aluminum die castings by hard anodizing.
Where a part design does not allow the production of a pressure-tight die casting through control of
porosity by gate and overflow die design, the location of ejector pins, and the reconfiguration of hardto-cast features, impregnation of aluminum die castings can be used. Systems employing anaerobics
and methacrylates are employed to produce sealed, pressure-tight castings with smooth surfaces. A
detailed discussion of finishing methods for aluminum die castings can be found in Product Design For
Die Casting.
Table A-3-1 Chemical Composition: Al Alloys
All single values are maximum composition percentages unless otherwise stated.
Aluminum Die Casting Alloys aE
Commercial: 360
ANSI/AA
360.0
A360
A360.0
380 b
380.0
A380 b
A380.0
383
383.0
384 b
384.0
B390*
B390.0
13
413.0
A13
A413.0
43
C443.0
218
518.0
Nominal
Comp:
Mg 0.5
Si 9.5
Cu 3.5
Si 8.5
Cu 3.5
Si 8.5
Cu 2.5
Si 10.5
Cu 3.8
Si 11.0
Cu 4.5
Si 17.0
Si 12.0
Si 12.0
Si 5.0
Mg 8.0
Mg 0.5
Si 9.0
Deta i led Composit ion

Silicon
Si
Iron
Fe
Copper
Cu
Magnesium
Mg
Manganese
Mn
Nickel
Ni
Zinc
Zn
Tin
Sn
Titanium
Ti
Others
Each
Total
Others c
Aluminum
Al
9.0-10.0
9.0-10.0
7.5-9.5
7.5-9.5
9.5-11.5
10.5-12.0 16.0-18.0 11.0-13.0 11.0-13.0 4.5-6.0
0.35
2.0
1.3
2.0
1.3
1.3
1.3
1.3
2.0
1.3
2.0
1.8
0.6
0.6
3.0-4.0
3.0-4.0
2.0-3.0
3.0-4.5
4.0-5.0
1.0
1.0
0.6
0.25
0.4-0.6
0.4-0.6
0.30 f
0.30 f
0.10
0.10
0.450.65
0.10
0.10
0.10
7.5-8.5
0.35
0.35
0.50
0.50
0.50
0.50
0.50
0.35
0.35
0.35
0.35
0.50
0.50
0.50
0.50
0.30
0.50
0.10
0.50
0.50
0.50
0.15
0.50
0.50
3.0
3.0
3.0
3.0
1.5
0.50
0.50
0.50
0.15
0.15
0.15
0.35
0.35
0.15
0.35
0.15
0.15
0.15
0.15
0.10
0.10
0.25
0.25
0.50
0.50
0.50
0.50
0.20
0.25
0.25
0.25
0.25
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Balance
a Analysis shall ordinarily be made only for the elements mentioned in this table. If, however, the presence of other elements is suspected, or indicated in the course of routine
analysis, further analysis shall be made to determine that the total of these other elements are not present in excess of specified limits. b With respect to mechanical properties, alloys
A380.0, 383.0 and 384.0 are substantially interchangeable. c For RoHS (the European Unions Directive on Restriction of Hazardous Substances) compliance, certification
of chemical analysis is required to ensure that the total others category does not exceed the following weight percent limits: 0.01% cadmium, 0.4% lead, and 0.1% mercury.
Hexavalent chromium does not exist in the alloys and therefore meets the 0.1% limit. D Notched Charpy. Sources: ASTM B85-92a; ASM; SAE; Wabash Alloys. E Registration
for REACH (the European Unions Directive on Registration, Evaluation, and Authorization of Chemicals) is not required for die castings, even if coated, since die castings are
considered articles. Notification may be required if some contained substances in the die casting or coating exceed the 0.1% total weight of the article level and are listed as SVHC
(substances of very high concern). f NADCA allows 0.30 maximum magnesium as opposed to 0.10. A380 with 0.30 magnesium has been registered with the Aluminum
Association as E380 and 383 with 0.30 magnesium as B383.
* Two other aluminum alloys, 361 and 369, are being utilized in limited applications where vibration and wear are of concern. There are also other heat treatable specialty alloys
available for structural applications, such as the Silafonts and AA365, and high ductility, high strength alloys such as Mercalloy and K-Alloy. Contact your alloy producer for more
information. Sources: ASTM B85-92a; Aluminum Association.
3-5
Alloy Data
NADCA
A-3-2-15
Typical values based on as-cast characteristics

for separately die cast specimens, not specimens cut
from production die castings.
STANDARD
Table A-3-2 Typical Material Properties: Al Alloys

Aluminum Die Casting Alloys
Commercial:
ANSI/AA
360
360.0
A360
380
A360.0 380.0
A380 EF 383 E
A380.0 383.0
384
384.0
B390*
B390.0
13
413.0
A13
43
218
A413.0 C443.0 518.0
Mecha nica l Proper t ies
Ultimate Tensile Strength

ksi
44
46
(303)
(317)
(MPa)
46
(317)
47
(324)
45
(310)
48
(331)
46
(317)
43
(296)
42
(290)
33
(228)
45
(310)
24
(165)
23
(159)
23
(159)
22
(152)
24
(165)
36
(248)
21
(145)
19
(131)
14
(97)
28
(193)
2.5
3.5
3.5
3.5
3.5
2.5
<1
2.5
3.5
9.0
5.0
75
75
80
80
75
85
120
80
80
65
80
28
(193)
26
(179)
28
(193)
27
(186)
29
(200)
25
(172)
25
(172)
19
(131)
29
(200)
3
(4)
3d
(4)
7
(9)
18
(124)
20
(138)
20
(138)
21
(145)
20
(138)
20
(138)
19
(131)
19
(131)
17
(117)
20
(138)
10.3
(71)
10.3
(71)
10.3
(71)
10.3
(71)
11.8
(81)
10.3
(71)
10.3
(71)
0.095
(2.63)
0.099
(2.74)
0.098
(2.71)
0.099
(2.74)
0.102
(2.82)
0.098
(2.71)
0.096
(2.66)
0.096
(2.66)
0.097
(2.69)
0.093
(2.57)
Yield Strength a
ksi
25
(172)
(MPa)
Elongation
% in 2in.
(51mm)
Hardness b
BHN
Shear Strength
ksi
(MPa)
Impact Strength
ft-lb
(J)
Fatigue Strength c
ksi
20
(138)
(MPa)
Youngs Modulus
psi x 10 6
10.3
(71)
(GPa)
Physica l Proper t ies

Density
lb/in 3
(g/cm3)
Melting Range
F
(C)
Specific Heat
BTU/lb F
(J/kg C)
0.095
(2.63)
1035-1105 1035-1105 1000-1100 1000-1100 960-1080 960-1080 950-1200 1065-1080 1065-1080 1065-1170 995-1150
(557-596) (557-596) (540-595) (540-595) (516-582) (516-582) (510-650) (574-582) (574-582) (574-632) (535-621)
0.230
(963)
0.230
(963)
0.230
(963)
Coefficient of Thermal Expansion

m in/inF
11.6
11.6
12.2
(21.0)
(21.0)
(22.0)
(m m/mK)
Thermal Conductivity
BTU/ft hrF
65.3
(113)
(W/m K)
Electrical Conductivity
30
% IACS
Poissons Ratio
0.33
0.230
(963)
0.230
(963)
0.230
(963)
0.230
(963)
0.230
(963)
12.1
(21.8)
11.7
(21.1)
11.6
(21.0)
10.0
(18.0)
11.3
(20.4)
11.9
(21.6)
12.2
(22.0)
13.4
(24.1)
65.3
(113)
55.6
(96.2)
55.6
(96.2)
55.6
(96.2)
55.6
(96.2)
77.4
(134)
70.1
(121)
70.1
(121)
82.2
(142)
55.6
(96.2)
29
27
23
23
22
27
31
31
37
24
0.33
0.33
0.33
0.33
0.33
a 0.2% offset. b 500 kg load, 10mm ball. c Rotary Bend 5 x 10
cycles. d Notched Charpy. Sources: ASTM B85-92a; ASM; SAE; Wabash Alloys. E A 0.3% Mg
version of A380 and 383 have been registered with the Aluminum Association as E380 and B383. F Higher levels of Mg and the addition of Sr to alloy A380 have shown
positive results. The limited data on pages 3-7 - 3-11 shows the effect.
8
* Two other aluminum alloys, 361 and 369, are being utilized in limited applications where vibration and wear are of concern. There are also other heat treatable specialty alloys
and processes available for structural applications, such as the Silafonts and AA365 (Aural 2), and high ductility, high strength alloys such as Mercalloy and K-Alloy.
Contact your alloy producer for more information. More information can also be obtained from Microstructures and Properties of Aluminum Die Casting Alloys Book, NADCA
Publication #215 and the High Integrity Aluminum Die Casting Book, NADCA Publication #307.
3-6
Alloy Data
NADCA
A-3-3-15
GUIDELINES
Die casting alloy selection requires evaluation not only of physical and mechanical properties,
and chemical composition, but also of inherent alloy characteristics and their effect on die
casting production as well as possible machining and final surface finishing.
This table includes selected die casting and other special characteristics which are usually
considered in selecting an aluminum alloy for a specific application.
The characteristics are rated from (1) to (5), (1) being the most desirable and (5) being the
least. In applying these ratings, it should be noted that all the alloys have sufficiently good
characteristics to be accepted by users and producers of die castings. A rating of (5) in one or
more categories would not rule out an alloy if other attributes are particularly favorable, but
ratings of (5) may present manufacturing difficulties.
The benefits of consulting a custom die caster experienced in casting the aluminum alloy being
considered are clear.
Table A-3-3 Die Casting And Other Characteristics: Al Alloys

(1 = most desirable, 5 = least desirable)
Aluminum Die Casting Alloys

360 A360 380 A380 383 384 390*
13
A13
43
218
360.0 A360.0 380.0 A380.0 383.0 384.0 B390.0 413.0 A413.0 C443.0 518.0
Commercial: ANSI/AA
Resistance to
Hot Cracking a
Pressure Tightness
Die-Filling Capacity b
Anti-Soldering to the Die c
Corrosion Resistance d
Machining Ease & Quality e
Polishing Ease & Quality f
Electroplating Ease & Quality g
Anodizing (Appearance) h
Chemical Oxide Protective Coating i
Strength at Elevated Temp. j
a Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature ranges. b Ability of molten alloy to flow readily in die
and fill thin sections. c Ability of molten alloy to flow without sticking to the die surfaces. Ratings given for anti-soldering are based on nominal iron compositions of
approximately 1%. d Based on resistance of alloy in standard type salt spray test. e Composite rating based on ease of cutting, chip characteristics, quality of finish,
and tool life. f Composite rating based on ease and speed of polishing and quality of finish provided by typical polishing procedure. g Ability of the die casting to take
and hold an electroplate applied by present standard methods. h Rated on lightness of color, brightness, and uniformity of clear anodized coating applied in sulphuric
acid electrolyte. i Rated on combined resistance of coating and prolonged heating at testing temperature. Sources: ASTM B85-92a; ASM; SAE
* Two other aluminum alloys, 361 & 369, are being utilized in limited applications where vibration and wear are of concern. There are also other heat treatable
specialty alloys available for structural applications, such as the Silafonts and AA365, and high ductility, high strength alloys such as Mercalloy and K-Alloy.
Contact your alloy producer for more information.
Note: Die castings are not usually solution heat treated. Low-temperature aging treatments may be used for stress relief or dimensional stability. A T2 or T5
temper may be given to improve properties. Because of the severe chill rate and ultra-fine grain size in die castings, their as-cast structure approaches that of the
solution heat-treated condition. T4 and T5 temper results in properties quite similar to those which might be obtained if given a full T6 temper. Die castings are
not generally gas or arc welded or brazed.
Additional A380 Alloy Tensile Data
(Data is from separately cast specimines in the naturally aged condition)
Alloys
Tensile ksi (MPa)
Yield ksi (MPa)
Elong %
A380 with 0.26% Mg
47.0 (201)
26.6 (183)
2.8
A380 with 0.33% Mg + 0.035% Sr*
45.7 (177)
28.5 (196)
2.4
A380 at 0.09% Mg
45.5 (243)
23.8 (135)
2.6
* Identified as AMC380* in research being conducted by WPI and funded by DoD/DLA. The values in this table
are the average mean values and are provided to indicate the effect of a higher magnesium content and additional
strontium. The properties shown do not represent design minimums and should be used for reference only.
3-7
Alloy Data
Table 1: Composition of Three Experimental Alloys as Compared to A380.
Composition (%)
A380
A380*
AMC380
AMC 1045Sr
Si
Cu
Mg
Fe
Mn
Zn
Ni
Ti
Sr
7.5-9.5
3-4
<0.1
<1.3
<0.5
<3
<0.5
7.0-8.0
3.8-4.2
0.08-0.12
0.63-0.73
0.47-0.53
2.0-3.0
<0.1
<0.2
<0.005
9-10
2.8-3.2
0.27-0.33
0.63-0.73
0.47-0.53
2.0-3.0
10.5-11.5
1.8-2.2
2.3-2.7
0.27-0.33
0.37-0.43
<0.3
<0.05
0.18-0.22 0.018-0.022
<0.01
0.018-0.022
Note: The experimental alloys were developed through research sponsored by NADCA, conducted at WPI, and funded by DOD/DLA.
Table 2: T
ensile properties of separately die cast specimens of the experimental
alloys compared to separately die cast specimens of alloy A380.
Alloy
A380
A380*
AMC 380*
AMC 1045Sr
UTS
YS
Gage
length
(inch) Value (Ksi) Vs A380 (%) Value (Ksi) Vs A380 (%)
1
2
1
2
1
2
1
2
45.6
1.3
22.7
0.7
42.8
1.1
46.3
0.6
42.9
0.8
49.9
1.1
46.2
1.2
53.4
1.3
+17.1
46.2
1.7
35.2
0.9
+13.4
3.72
0.34
-0.2
2.33
0.28
-39.2
1.16
0.19
+56.2
10.6
1.4
11.1
0.3
10.7
1.2
-2.7
2.33
0.13
+55.1
11.3
0.5
+20.8
2.64
0.2
Value
(103 Ksi)
11.0
1.1
4.63
0.38
+19.8
38.0
0.8
+8.1
2.33
0.24
+22.9
29.1
0.6
+7.9
+2.8
27.9
0.7
+9.4
3.83
0.48
+4.4
25.0
0.6
+0.3
Vs A380 (%)
23.7
0.5
+1.4
Modulus of Elasticity
Value (%)
24.3
0.5
-50.2
11.4
0.2
11.9
0.8
11.3
0.3
Vs A380 (%)
-3.5
-1.1
-2.8
+1.1
+8.7
+0.3
Note: The experimental alloys were developed through research sponsored by NADCA, conducted at WPI, and funded by DOD/DLA. The properties shown do not
represent design minimums and should be used for reference only.
Table 3: T
ensile properties measured on specimens that were cut from die cast components.
Alloy
A380
AMC 380
AMC 1045Sr
AMC 1045
UTS
YS
Value (Ksi) Vs A380 (%) Value (Ksi) Vs A380 (%)

39.4
1.8
47.1
3.2
54.9
2.6
53.9
2.8
+19.6
+39.4
+36.8
21.4
1.7
31.0
1.4
42.2
4.6
45.7
2.4
+45.0
+97.4
+114
Value (%)
2.32
0.47
2.38
0.64
1.76
0.68
1.17
0.29
Modulus of Elasticity
Vs A380 (%)
+2.7
-24.3
-49.5
Value (103 Ksi)

235.2
16.0
302.6
28.4
350.4
21.1
339.8
19.2
Vs A380 (%)
+28.6
+49.0
+44.4
Note: The experimental alloys were developed through research sponsored by NADCA, conducted at WPI, and funded by DOD/DLA. The properties shown do not
represent design minimums and should be used for reference only.
3-8
Alloy Data
Table 4: Elevated temperature and room temperature tensile properties of the
experimental alloys and commercial A380 alloy. Tests were conducted
at temperature on separately die cast tensile specimens.
Alloy
Test Condition
TS (Ksi)
YS (Ksi)
e (%)
Modules of
Elasticity
(X10 3Ksi)
25C (as-cast)
45.61.3
22.70.7
3.830.48
11.01.1
0.5 h
42.00.6
23.30.3
4.20.63
10.20.5
500 h
42.70.6
25.40.4
4.170.6
9.50.4
1000 h
43.40.3
26.50.2
4.200.1
9.80.5
0.5 h
30.10.9
20.70.3
6.170.78
8.40.6
500 h
25.00.3
17.60.3
6.72.0
8.40.7
1000 h
24.20.3
17.00.3
7.21.3
7.62.0
46.30.6
23.70.5
4.630.38
10.61.4
0.5 h
41.10.8
23.60.4
4.460.53
9.60.7
500 h
41.50.8
25.40.3
4.180.6
8.70.9
1000 h
42.50.6
26.50.2
4.290.4
9.80.6
0.5 h
30.10.6
23.10.4
5.010.14
8.40.6
500 h
25.60.4
19.20.6
5.81.0
9.20.6
1000 h
24.40.2
18.20.2
6.30.6
8.21.6
49.91.1
27.90.7
3.720.34
10.71.2
0.5 h
46.61.0
28.10.5
4.200.22
9.70.3
500 h
46.50.7
30.30.4
3.700.2
9.80.4
1000 h
46.90.6
32.20.8
3.210.2
9.90.4
0.5 h
36.50.5
28.50.5
4.510.35
8.70.4
500 h
31.80.8
24.90.8
4.30.4
9.10.6
1000 h
29.30.7
22.90.6
4.41.0
8.61.0
53.41.3
35.20.9
2.330.28
11.90.8
0.5 h
50.11.3
34.41.5
2.600.43
10.10.2
500 h
50.22.7
37.00.6
2.270.6
9.80.4
1000 h
50.41.1
39.00.9
1.890.3
10.00.4
0.5 h
45.00.4
36.30.6
3.180.29
8.80.5
500 h
33.50.2
25.00.2
4.00.4
9.50.7
1000 h
30.80.5
22.30.5
5.00.6
8.40.4
100C
A380
200C
25C (as-cast)
100C
A380*
200C
25C (as-cast)
100C
AMC380
200C
25C (as-cast)
100C
AMC1045Sr
200C
Note: The experimental alloys were developed through research sponsored by NADCA, conducted at WPI, and funded by DOD/
DLA. The properties shown do not represent design minimums and should be used for reference only.
3-9
Alloy Data
Table 5: Tensile properties of the experimental alloys at temperature and after
exposure to temperature. Specimens were separately die cast.
Alloy
A380
Test Condition
TS (Ksi)
YS (Ksi)
e (%)
Modules of
Elasticity
(X10 3Ksi)
25C (as-cast)
45.61.3
22.70.7
3.830.48
11.01.1
0.5 h
45.00.9
21.80.2
3.250.47
11.81.2
500 h
38.40.7
22.21.9
2.910.77
11.50.5
1000 h
38.50.2
22.41.5
2.810.49
12.41.7
0.5 h
30.10.9
20.70.3
6.170.78
8.40.6
500 h
25.00.3
17.60.3
6.72.0
8.40.7
1000 h
24.20.3
17.00.3
7.21.3
7.62.0
46.30.6
23.70.5
4.630.38
10.61.4
0.5 h
41.43.1
25.01.9
2.720.42
11.21.6
500 h
39.00.2
22.70.4
3.340.50
9.10.8
1000 h
37.30.1
21.30.2
3.130.11
12.50.11
0.5 h
30.10.6
23.10.4
5.010.14
8.40.6
500 h
25.60.4
19.20.6
5.81.0
9.20.6
1000 h
24.40.2
18.20.2
6.30.6
8.21.6
49.91.1
27.90.7
3.720.34
10.71.2
0.5 h
48.00.7
27.60.5
3.130.22
12.51.7
500 h
43.90.8
29.31.0
2.330.36
11.62.0
1000 h
45.11.4
29.50.8
2.680.31
12.22.5
0.5 h
36.50.5
28.50.5
4.510.35
8.70.4
500 h
31.80.8
24.90.8
4.30.4
9.10.6
1000 h
29.30.7
22.90.6
4.41.0
8.61.0
53.41.3
35.20.9
2.330.28
11.90.8
0.5 h
49.53.5
36.03.3
1.420.39
12.71.4
500 h
45.11.3
28.50.6
2.470.52
12.21.7
1000 h
44.11.2
25.70.7
3.130.09
12.00.3
0.5 h
45.00.4
36.30.6
3.180.29
8.80.5
500 h
33.50.2
25.00.2
4.00.4
9.50.7
1000 h
30.80.5
22.30.5
5.00.6
8.40.4
Cooled
to
25C
Tested
at
200C
25C (as-cast)
A380*
Cooled
to
25C
Tested
at
200C
25C (as-cast)
AMC380
Cooled
to
25C
Tested
at
200C
25C (as-cast)
AMC1045Sr
Cooled
to
25C
Tested
at
200C
3-10
Alloy Data
Table 6: Fatigue strength of experimental alloys as compare to A380. Specimens were
separately die cast and tested using the R.R Moore rotating bending fatigue test.
Alloy
Cycles
Maximum
stress (ksi)
Change vs.
A380
A380
A380*
AMC380
AMC1045Sr
1x10 8
5x10 8
1x10 8
5x10 8
1x10 8
5x10 8
1x10 8
5x10 8
22.6
22.1
20.4
20.1
23.3
22.5
24.4
24.1
-9.75%
-9.22%
+3.34%
+1.39%
+8.33%
+8.98%
Table 7: Composition of suggested alloys and company specific alloys as compared to A380
A380
Si
7.5-9.5
Cu
Mg
Fe
High Mg A380
7.5-9.5
3-4
0.5
3-4
0.1
Composition (%)
Mn
Zn
Ni
Ti
Sr
Other
1.3
0.5
0.5
0.5
1.3
0.5
0.5
0.5
F380
8.5-9.5
3-4
0.1-0.3
0.4
0.25-0.35
0.1
0.05-0.07
0.5
B360
9.0-10.0
0.25
0.4-0.6
0.4
0.25-0.35
0.5
0.1
0.05-0.07
0.25
Gibbsalloy MN
0.1-0.3
0.1
2.6-3.7
0.2-0.5
0.4-1.0
0.05
0.03-0.07
0.5
Table 8: Tensile properties of separately die cast specimens of the suggested and company
specific alloys compared to separately die cast specimens of alloy A380.
UTS (ksi)
YS (ksi)
e (%)
Hi Mg 380
45.8
27.2
3.0
Hi Mg 380-T5
46.7
39.3
1.2
F380
46.1
23.4
5.0
B360
46.6
23.5
6.1
A380
Alloy
B360-T5
47.0
23.0
3.5
52
37.1
3.6
Gibbsalloy MN
30.6
15.9
12.1
Gibbsalloy MN-T5
32.5
18.5
11.7
Note: This data was developed through research sponsored by NADCA and funded by DOD/DLA and NADCA. The
properties shown do not represent design minimums and should be used for reference only.
3-11
Alloy Data
3
Aluminum Metal Matrix Composites
Selecting Aluminum Composites

Aluminum metal matrix composites (MMC) are aluminum-based alloys reinforced with up to 20%
silicon carbide (SiC) particles, which are now being used for high-performance die cast components.
The mechanical properties of ASTM test specimens made from these materials typically exceed
those of most aluminum, magnesium, zinc and bronze components produced by die casting, and
match or approach many of the characteristics of iron castings and steel at lighter weight.
The expected properties of MMC parts are higher stiffness and thermal conductivity,
improved wear resistance, lower coefficient of thermal expansion, and higher tensile and fatigue
strengths at elevated temperature, with densities within 5% of aluminum die casting alloys.
These composites can also yield castings with reduced porosity.
Preliminary data also indicates that less vibrational noise is generated by parts made from these
composites, under certain conditions, than by identical parts made from unreinforced aluminum.
Duralcan F3D.10%v/v and 20%v/v aluminum metal matrix composites reinforced with SiC
ceramic powder are general purpose die casting alloys.
Duralcan F3N.10%v/v and 20%v/v aluminum metal matrix composites reinforced with SiC
ceramic powder contain virtually no copper or nickel and are designed for use in corrosion
sensitive applications. All of these composites are heat treatable.
Al-MMCs are significantly more abrasive to cutting tools than all other aluminum die cast and
gravity cast alloys, except for hypereutectic Al-Si alloys (those containing primary Si phases).
Coarse grades of polycrystalline diamond (PCD) tools are recommended for anything more
than prototype quantities of machining.
With the proper tooling, Al-MMC can be readily turned, milled, or drilled. However, cutting speeds are lower and feed rates are higher than for unreinforced alloys. General machining
guidelines are described in Volume 1 of the SME Tool & Manufacturing Engineers Handbook.

Surface treatments are generally applied to aluminum MMC to provide a protective barrier to
environmental exposure, to provide decorative finish, or to reduce the abrasiveness of the MMC
to a counterface material. Because of the inherently high wear resistance of the Al-MMCs,
surface treatments on these materials are generally not used to improve their wear resistance.
Decorative finishes can be applied by painting, powder coat finishing, epoxy finishing and
plating, using procedures similar to those used for conventional aluminum alloys.
Although conventional and hard-coat anodized finishes can be applied to Al-MMC die
castings, the results are not as cosmetically appealing as for conventional aluminum. The
presence of the SiC particles results in a darker, more mottled appearance. This problem can be
minimized, although not entirely eliminated, by using the darker, more intensely colored dyes
to color the anodic coatings. Another problem often noted is that the presence of the ceramic
particles produces a rougher surface, particularly after chemical etching. This, in turn, leads to a
less lustrous anodic coating than usually seen with unreinforced aluminum.
Recommended procedures for painting, plating and anodizing Duralcan MMCs can be obtained
through Rio Tinto Alcan, 2040 Chemin de la Reserve, Chicoutimi (Quebec) G7H 5B3, Canada.
This aluminum composite subsection presents guideline tables for chemical composition, typical
properties, and die casting and other characteristics for the two families of aluminum matrix composite alloys for die casting. Design engineering tolerancing guidelines have yet to be developed.
Rio Tinto Alcan - Dubuc Works, produces Duralcan metal matrix composites for die casting
using a patented process and proprietary technology, mixing ceramic powder into molten aluminum.
Further technical and application information can be obtained from Rio Tinto Alcan, 2040 Chemin
de la Reserve, Chicoutimi (Quebec) G7H 5B3, Canada.
3-12
Alloy Data
NADCA
A-3-4-15
STANDARD
Table A-3-4 Chemical Composition: Al-MMC Alloys

Duralcan Aluminum Metal Matrix Composite Alloys B
F3D.10S-F
F3D.20S-F
F3N.10S-F
F3N.20S-F
10%
20%
10%
20%
9.50-10.50
9.50-10.50
9.50-10.50
9.50-10.50
0.8-1.20
0.8-1.20
0.8-1.20
0.8-1.20
3.0-0.50
3.0-3.50
0.20 max.
0.20 max.
0.30-0.50
0.30-0.50
0.50-0.70
0.50-0.70
0.50-0.80
0.50-0.80
0.50-0.80
0.50-0.80
1.00-1.50
1.00-1.50
0.05 max.
0.20 max.
0.20 max.
0.20 max.
Zinc
Zn
0.05 max.
0.05 max.
0.05 max.
0.05 max.
Aluminum
Al
0.10 Total
0.03 max.
0.10 Total
0.03 max.
0.10 Total
0.03 max.
0.10 Total
0.03 max.
Balance
Balance
Balance
Balance
Commercial:
SiC Particulate Volume
Percent
Silicon
Si
Iron
Fe
Copper
Cu
Magnesium
Mg
Manganese
Mn
Nickel
Ni
Titanium
Ti
Total
Others A
For RoHS (the European Unions Directive on Restriction of Hazardous Substances) compliance, certification of chemical
analysis is required to ensure that the total others category does not exceed the following weight percent limits: 0.01%
cadmium, 0.4% lead, and 0.1% mercury. Hexavalent chromium does not exist in the alloys and therefore meets the 0.1%
limit. B Registration for REACH (the European Unions Directive on Registration, Evaluation, and Authorization
of Chemicals) is not required for die castings, even if coated, since die castings are considered articles. Notification may be
required if some contained substances in the die casting or coating exceed the 0.1% total weight of the article level and are
listed as SVHC (substances of very high concern).
Source: Rio Tinto Alcan Dubuc Works
3-13
NADCA
Alloy Data
A-3-5-15
STANDARD
Table A-3-5 Typical Material Properties: Al-MMC Alloys
Typical values based on as-cast characteristics for separately die cast specimens, not specimens
cut from production die castings.
Duralcan Aluminum Metal Matrix Composite Alloys
F30D.10S-F
F30D.20S-F
F30N.10S-F
F30N.20S-F
Ultimate Tensile Strength a

ksi
50
(345)
(MPa)
51
(352)
45
(310)
44
(303)
Yield Strength a
ksi
(MPa)
35
(241)
44
(303)
32
(221)
36
(248)
Elongation a
% in 2in. (51mm)
1.2
0.4
0.9
0.5
77
82
56
73
1.9
0.7
1.4
0.7
22
(152)
22
(152)
Elastic Modulus a
psi x 10 6
(GPa)
10.3
(71)
10.3
(71)
20
(140)
15.7
(108.2)
Density
lb/in 3
(g/cm3)
0.0997
(2.76)
0.1019
(2.82)
0.0957
(2.65)
0.0979
(2.71)
Melting Range
F
(C)
975-1060
(524-571)
975-1060
(524-571)
1067-1112
(575-600)
1067-1112
(575-600)
Specific Heat
BTU/lb F @ 77 F
(J/kg C @ 22 C)
0.201
(841.5)
0.198
(829.0)
0.208
(870.9)
0.193
(808.1)
Average Coefficient of Thermal Expansion

m in/inF
10.7
9.4
(19.3)
(16.9)
(m m/mK)
11.9
(21.4)
9.2
(16.6)
BTU/ft hrF @ 72 F
(W/m K @ 22 C)
Commercial:
Rockwell Hardness a
HRB
Impact Energy b
Charpy impact ASTM
E-23
(J)
Fatigue Strength C
ksi
(MPa)
71.6
(123.9)
83.2
(144.0)
93.0
(161.0)
97.1
(168.1)
% IACS @ 22 C
22.0
20.5
32.7
24.7
Poissons Ratio
0.296
0.287
0.293
a Based on cast-to-size tensile bars. b Cast-to-size test specimens. c Axial fatigue, R=0.1, RT (room temperature), 1 x
107 cycles. Source: Alcan ECP Canada
3-14
Alloy Data
NADCA
A-3-6-15
GUIDELINES
considered in selecting an aluminum matrix alloy for a specific application.
The benefits of consulting a custom die caster experienced in casting the aluminum matrix alloy
being considered are clear.
Table A-3-6 Die Casting and Other Characteristics: Al-MMC Alloys

Commercial: ANSI/AA
Duralcan Aluminum Metal Matrix Composite Alloys

F3D.10S-F
F3D.20S-F
F3N.10S-F
F3N.20S-F
Resistance to Hot Cracking a
Pressure Tightness
Electroplating Ease & Quality g
Anodizing (Appearance) h
Anodizing (Protection)
Strength at Elevated Temp. I
Resistance to Wear
A Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature range. B Ability
of molten alloy to flow readily in die and fill thin sections. C Ability of molten alloy to flow without sticking to the die surfaces. D
Based on resistance of alloy in standard type salt spray test. E Composite rating based on ease of cutting, ship characteristics, quality
of finish, and tool life. F Composite rating based on ease and speed of polishing and quality of finish provided by typical polishing
procedures. G Ability of the die casting to take and hold an electroplate applied by present standard methods. H Rated on lightness
of color, brightness, and uniformity of clear anodized coating applied in sulphuric acid electrolyte. Generally aluminum die castings
are unsuitable for light color anodizing where pleasing appearance is required. I Rating based on tensile and yield strengths at
temperatures up to 500 F (260 C), after prolonged heating at testing temperatures. Source: Alcan ECP Canada
Note: There are additional metal matrix composites materials being developed. These include Aluminum and Magnesium matrix composites and nano-composites are being produced by means of SHS (Self-propagating high-temperature synthesis) technology under NADCA
sponsored research projects. Contact the NADCA Technology Department for more information about these composite materials.
3-15
Alloy Data
4
Copper Alloys
Selecting Copper (Brass) Alloys

Copper alloy (Cu) die castings (brass and bronze) have the highest mechanical properties and
corrosion resistance of all die cast materials.
The standard copper-base alloys in general use are readily die cast in intricate shapes. The
high temperatures and pressures at which they are cast 1800 to 1950F (982-1066C)
result in shortened die life, compared to the other nonferrous alloys. While this will result in
higher die replacement costs for brass castings, total product cost can be lower compared to
brass machined parts or brass investment castings.
Where added strength, corrosion resistance, wear resistance and greater hardness are
required for a product, the possible economies of brass die castings over other production
processes should be carefully considered.
This copper alloy subsection presents guideline tables for chemical composition, typical
properties, and die casting, machining and finishing characteristics for the most commonly
used copper die casting alloys. This data can be used in combination with design engineering
tolerancing guidelines for copper die casting and compared with the guidelines for other alloys
in this section and in the design engineering section.
Copper alloy 858 is a general-purpose, lower-cost yellow brass alloy with good machinability
and soldering characteristics.
Alloy 878 has the highest mechanical strength, hardness and wear resistance of the copper die
casting alloys, but is the most difficult to machine. It is generally used only when the application requires its high strength and resistance to wear, although its lower lead content makes it
environmentally more attractive.
Where environmental and health concerns are a factor in an application, those alloys with low
lead content, as shown in table A-3-7, will be increasingly preferred.
Some examples of copper alloys in die casting are lock cases, lids and shrouds for water meters,
door hardware, electrical floor plates, plumbing hardware and locomotive components.
Machining
Copper alloy die castings in general are more difficult to machine than other nonferrous components, since their excellent conductivity results in rapid heating during machining operations.
However, there are significant differences in machining characteristics among the copper alloys,
as can be determined from Table A-3-9.
Ratings in Table A-3-9 are based on free machining yellow brass as a standard of 100. Most
copper alloys are machined dry. Three of the six alloys listed have a rating of 80, which is
excellent. Copper alloys 878 and 865 are not difficult to machine if carbide tools and cutting oil
are used. The chips from alloy 878 break up into fine particles while alloy 865 produces a long
spiral which does not break up easily into chips.
Surface Finishing Systems

The temperature characteristics of copper alloy castings require special care in surface finishing.
While a range of processes are available, electroplating is especially effective. Brass castings yield
a bright chrome plate finish equal to or superior to zinc.
Natural surface color ranges from a golden yellow for the yellow brass, to a buff brown for the
silicon brass alloys, to a silver color for the white manganese alloys. Copper alloys may be buffed and
polished to a high luster. Polishing shines the metal; sand or shot blasting will give it a satin finish.
Final finishing choices are available through chemical and electrochemical treatments which
impart greens, reds, blues, yellows, browns, black, or shades of gray. Clear organic finishes, consisting of nitrocellulose, polyvinyl fluoride or benzotriazole, are also available for copper alloys.
For more detailed finishing information contact the Copper Development Association Inc.,
260 Madison Ave., New York, NY 10016 or visit www.copper.org.
3-16
Alloy Data
NADCA
A-3-7-15
Table A-3-7 Chemical Composition: Cu Alloys
STANDARD
Commercial:
ANSI/AA
Nominal
Comp:
Copper Die Casting Alloys a

857
C85700
Yellow Brass
Cu 63.0
Al 0.3
Pb 1.0
Sn 1.0
Zn 36.0
858
C85800
Yellow Brass
Cu 61.5
Pb 1.0
Sn 1.0
Zn 36.0
C
865
C86500
Manganese
Bronze
Cu 58.0
Al 1.0
Fe 1.2
Sn 0.5
Mn 0.8
Zn 39.0
878
C87800
Si Bronze
Cu 82.0
Si 4.0
Zn 14.0
997.0
C99700
White
Tombasil
Cu 56.5
Al 1.8
Pb 1.5
Mn 13.0
Ni 5.0
Zn 22.0
997.5
C99750
White Brass
Cu 58.0
Al 1.6
Mn 20.0
Pb 1.5
Zn 20.0

Copper
Cu
Tin
Sn
Lead
Pb B
Zinc
Zn
Iron
Fe
Aluminum
Al
58.0-64.0
57.0 min
55.0-60.0
80.0-84.2
54.0 min
0.5-1.5
1.5
1.0
0.25
1.0
0.8-1.5
1.5
0.4
0.09
2.0
0.5-2.5
32.0-40.0
31.0-41.0
36.0-42.0
12.0-16.0
19.0-25.0
17.0-23.0
0.7
0.50
0.4-2.0
0.15
1.0
1.0
0.8
0.55
0.5-1.5
0.15
0.5-3.0
0.25-3.0
0.25
0.1-1.5
0.15
11.0-15.0
17.0-23.0
4.0-6.0
5.0
99.7 min.
99.7 min.
Manganese
Mn
Antimony
Sb
Nickel (incl.
Cobalt)
Ni
0.05
1.0
Sulphur
S
Phosphorus
P
Silicon
Si
0.05
Arsenic
As
0.5
55.0-61.0
0.05
1.0
0.20
0.05
0.05
0.01
0.01
0.25
3.8-4.2
0.05
0.05
Magnesium
Mg
0.01
Copper + Sum
98.7 min.
of Named
Elements B
98.7 min.
99.0 min.
99.5 min.
a Analysis shall ordinarily be made only for the elements mentioned in this table. If, however, the presence of other elements is suspected, or indicated in the course
of routine analysis, further analysis shall be made to determine that the total of these other elements are not present in excess of specified limits. B For RoHS (the
European Unions Directive on Restriction of Hazardous Substances) compliance, certification of chemical analysis is required to ensure that the total others
category does not exceed the following weight percent limits: 0.01% cadmium, 0.4% lead, and 0.1% mercury. Hexavalent chromium does not exist in the alloys and
therefore meets the 0.1% limit. c Registration for REACH (the European Unions Directive on Registration, Evaluation, and Authorization of Chemicals) is
not required for die castings, even if coated, since die castings are considered articles. Notification may be required if some contained substances in the die casting or
coating exceed the 0.1% total weight of the article level and are listed as SVHC (substances of very high concern).
3-17
NADCA
Alloy Data
A-3-8-15
STANDARD
Table A-3-8 Typical Material Properties: Cu Alloys
Typical values based on as-cast characteristics for separately die cast specimens, not specimens
Copper Die Casting Alloys
858
C85800
Yellow
Brass
865
C86500
Mn
Bronze
878
997.0
997.5
C87800 C99700 C99750
Si Bronze White
White
Tombasil Brass

ksi
50
(344)
(MPa)
55
(379)
71
(489)
85
(586)
65
(448)
65
(448)
18
(124)
30
(207)
28
(193)
50
(344)
27
(186)
32
(221)
15
15
30
25
15
30
75
5560HRB
100
8590HRB
125
(@300kg)
110
40
(54)
32
(43)
70
(95)
75
(102)
20
(138)
19
(128)
Youngs Modulus
psi x 10 6
(GPa)
14
(87)
15
(103.4)
15
(103.4)
20
(137.8)
16.5
(113.7)
17
(117.1)
Density
lb/in 3 @ 68 F
(g/cm3) @20 C
0.304
(8.4)
0.305
(8.44)
0.301
(8.33)
0.300
(8.3)
0.296
(8.19)
0.29
(8.03)
1675-1725
(913-940)
1600-1650
(871-899)
1583-1616
(862-880)
1510-1680
(821-933)
1615-1655
(879-902)
1505-1550
(819-843)
0.09
(377.0)
0.09
(377.0)
0.09
(377.0)
0.09
(377.0)
0.09
(377.0)
0.09
(377.0)
11.3
(20.3)
10.9
(19.6)
10.9
(19.6)
13.5
(24.3)
48.5
(83.9)
49.6
(85.8)
16.0
(27.7)
16.0
(27.7)
22
20
22
6.7
3.0
2.0
80
80
26
40
80
80
Commercial:
ANSI/AA:
Common Name:
857
C85700
Yellow
Brass
Yield Strength a
ksi
(MPa)
Elongation
% in 2in. (51mm)
Hardness
BHN (500)
Impact Strength
ft-lb
(J)
Fatigue Strength
ksi
(MPa)
Melting Range
F
(C)
Specific Heat
BTU/lb F @ 68 F
(J/kg K @ 293 K)
Average Coefficient of Thermal Expansion

m in/inF x 10 -6
12
12
(21.6)
(21.6)
(m m/mC x 10 -6)
BTUft/(hrft 2F) @ 68 F 48.5
(83.9)
(W/m K @ 20 C)
% IACS @ 20 C
Poissons Ratio
a Tensile yield strength at -0.5% extension under load. Sources: ASTM B176-93a and Copper Development Association.
3-18
Alloy Data
NADCA
A-3-9-15
GUIDELINES
considered in selecting a copper alloy for a specific application.
The benefits of consulting a custom die caster experienced in casting the copper alloy being
Table A-3-9 Die Casting and Other Characteristics: Cu Alloys

Copper Die Casting Alloys

857
C85700
Commercial:
UNS:
858
865
878
997.0
997.5
C85800 C86500 C87800 C99700 C99750
Resistance to Hot Cracking a
Pressure Tightness
As Cast Surface Smoothness

High Temperature Strength h
Electroplating Ease & Quality
A Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature range. B Ability
of molten alloy to flow readily in die and fill thin sections. C Ability of molten alloy to flow without sticking to the die surfaces.
D Based on resistance of alloy in standard type salt spray test. E Composite rating based on ease of cutting, chip characteristics,
quality of finish, and tool life. F Composite rating based on ease and speed of polishing and quality of finish provided by typical
polishing procedure. G Ability of the die casting to take and hold an electroplate applied by present standard methods. H Rating
based on tensile and yield strengths at temperatures up to 500F (260C), after prolonged heating at testing temperature. Sources:
ASTM B176-93a; R. Lavin & Sons, Inc.
3-19
Alloy Data
5
Magnesium Alloys
Selecting Magnesium Alloys

Magnesium (Mg) has a specific gravity of 1.74 g/cc, making it the lightest commonly used
structural metal.
This magnesium alloy subsection presents guideline tables for chemical composition, typical
properties, and die casting, machining and finishing characteristics for seven magnesium alloys.
This data can be used in combination with design engineering tolerancing guidelines for magnesium die casting and can be compared with the guidelines for other alloys in this section and in
the design engineering section.
Alloy AZ91D and AZ81 offer the highest strength of the commercial magnesium die
casting alloys.
Alloy AZ91D is the most widely-used magnesium die casting alloy. It is a high-purity alloy with
excellent corrosion resistance, excellent castability, and excellent strength. Corrosion resistance is
achieved by enforcing strict limits on three metallic impurities: iron, copper and nickel.
AZ81 use is minimal since its properties are very close to those of AZ91D. Alloys AM60B,
AM50A and AM20 are used in applications requiring good elongation, toughness and impact
resistance combined with reasonably good strength and excellent corrosion resistance. Ductility
increases at the expense of castability and strength, as aluminum content decreases. Therefore, the
alloy with the lowest aluminum content that will meet the application requirements should be chosen.
Alloys AS41B and AE42 are used in applications requiring improved elevated temperature
strength and creep resistance combined with excellent ductility and corrosion resistance. The
properties of AS41B make it a good choice for crankcases of air-cooled automotive engines.
Among the more common applications of magnesium alloys can be found the following: auto
parts such as transfer cases, cam covers, steering columns, brake and clutch pedal brackets,
clutch housings, seat frames, and dashboard supports. Non-automotive products would include
chain saws, portable tools, vacuum cleaners, lawn mowers, household mixers, floor polishers,
blood pressure testing machines, projectors, cameras, radar indicators, tape recorders, sports
equipment, calculators, postage meters, computers, telecommunications equipment, fractional
horsepower motors, levels, sewing machines, solar cells, snowmobiles and luggage.
Machining
The magnesium alloys exhibit the best machinability of any group of commercially used metal alloys. Special precautions must routinely be taken when machining or grinding magnesium castings.

Decorative finishes can be applied to magnesium die castings by painting, chromate and
phosphate coatings, as well as plating. Magnesium castings can be effectively plated by applying
an initial immersion zinc coating, followed by conventional copper-nickel-chromium plating
procedure generally used for plating zinc metal/alloys.
Magnesium underbody auto parts, exposed to severe environmental conditions, are now used
with no special coatings or protection. Other Mg die castings, such as computer parts, are
often given a chemical treatment. This treatment or coating protects against tarnishing or slight
surface corrosion which can occur on unprotected magnesium die castings during storage in
moist atmospheres. Painting and anodizing further serve as an environmental corrosion barrier.
Improved wear resistance can be provided to magnesium die castings with hard anodizing or
hard chrome plating.
A detailed discussion of finishing methods for magnesium die castings can be found in
Product Design For Die Casting.
3-20
Alloy Data
NADCA
A-3-10-15
STANDARD
Table A-3-10 Chemical Composition: Mg Alloys
Commercial:
Nominal Comp:
Magnesium Die Casting Alloys a
F
AM60B B AM50A B
AM20 B
AE42 B
AS41B B
AZ91D A
AZ81 B
Al 9.0
Zn 0.7
Mn 0.2
Al 8.0
Zn 0.7
Mn 0.22
Al 6.0
Mn 0.3
Al 5.0
Mn 0.35
Al 2.0
Mn 0.55
Al 4.0
RE 2.4
Mn 0.3
Al 4.0
Si 1.0
Mn 0.37
8.3-9.7
7.0-8.5
5.5-6.5
4.4-5.4
1.7-2.2
3.4-4.6
3.5-5.0
0.35-1.0
0.3-1.0
0.22 max
0.22 max
0.1 max
0.22 max
0.12 max
0.15-0.50 C
0.17 min
0.24-0.6 C
0.26-0.6 C
0.5 min
0.25 D
0.35-0.7 C
0.10 max
0.05 max
0.10 max
0.10 max
0.10 max
0.5-1.5
0.005 C
0.004 max
0.005 C
0.004 C
0.005 max
0.005 D
0.0035 C
0.030
0.015
0.010
0.010
0.008
0.05
0.02
0.002
0.001
0.002
0.002
0.001
0.005
0.002
1.8-3.0
0.02
0.01
0.02
0.02
0.01
0.02
0.02
Balance
Balance
Balance
Balance
Balance
Balance
Balance

Aluminum
Al
Zinc
Zn
Manganese
Mn
Silicon
Si
Iron
Fe
Copper, Max
Cu
Nickel, Max
Ni
Rare Earth,
Total
RE
Others
Each E
Magnesium
Mg
A ASTM B94-03, based on die cast part. B Commercial producer specifications, based on ingot. Source: International Magnesium Association. C In alloys
AS41B, AM50A, AM60B and AZ91D, if either the minimum manganese limit or the maximum iron limit is not met, then the iron/manganese ratio shall not
exceed 0.010, 0.015, 0.021 and 0.032, respectively. D In alloy AE42, if either the minimum manganese limit or the maximum iron limit is exceeded, then
the permissible iron to manganese ratio shall not exceed 0.020. Source: ASTM B94-94, International Magnesium Assn. E For RoHS (the European Unions
Directive on Restriction of Hazardous Substances) compliance, certification of chemical analysis is required to ensure that the total others category does not
exceed the following weight percent limits: 0.01% cadmium, 0.4% lead, and 0.1% murcury. Hexavalent chromium does not exist in the alloys and therefore meets
the 0.1% limit. F Registration for REACH (the European Unions Directive on Registration, Evaluation, and Authorization of Chemicals) is not required for
die castings, even if coated, since die castings are considered articles. Notification may be required if some contained substances in the die casting or coating exceed
the 0.1% total weight of the article level and are listed as SVHC (substances of very high concern).
* There are additional magnesium alloys that have been and are being developed for elevated temperature and creep resistant applications. See the data table on
page 3-24. Contact your alloy producer for more information.
3-21
NADCA
Alloy Data
A-3-11-15
for separately die cast specimens, not specimens
STANDARD
Table A-3-11 Typical Material Properties: Mg Alloys

Magnesium Die Casting Alloys
Commercial:
AZ91D
AZ81
AM60B
AM50A
AM20
AE42
AS41B
Ultimate Tensile Strength B

ksi
34
(230)
(MPa)
32
(220)
32
(220)
32
(220)
32
(220)
27
(185)
33
(225)
Yield Strength E B
ksi
(MPa)
21
(150)
19
(130)
18
(120)
15
(105)
20
(140)
20
(140)
N/A
19
(130)
N/A
N/A
N/A
20
(140)
6-8
6-10
8-12
8-10
75
72
62
57
47
57
75
20
(140)
20
(140)
N/A
N/A
N/A
N/A
N/A
1.6
(2.2)
N/A
4.5
(6.1)
7.0
(9.5)
N/A
4.3
(5.8)
3.0
(4.1)
10
(70)
10
(70)
10
(70)
10
(70)
10
(70)
N/A
N/A
160
(373)
160
(373)
160
(373)
160
(373)
160
(373)
160
(373)
160
(373)
6.5
(45)
6.5
(45)
6.5
(45)
6.5
(45)
6.5
(45)
6.5
(45)
6.5
(45)
Density
lb/in 3
(g/cm 3)
0.066
(1.81)
0.065
(1.80)
0.065
(1.80)
0.064
(1.78)
0.063
(1.76)
0.064
(1.78)
0.064
(1.78)
Melting Range
F
(C)
875-1105
(470-595)
915-1130
(490-610)
1005-1140
(540-615)
1010-1150
(543-620)
1145-1190
(618-643)
1050-1150
(565-620)
1050-1150
(565-620)
Specific Heat B
BTU/lb F
(J/kg C)
0.25
(1050)
0.25
(1050)
0.25
(1050)
0.25
(1050)
0.24
(1000)
0.24
(1000)
0.24
(1000)
Coefficient of Thermal Expansion B

m in/inF
13.8
(25.0)
(m m/mK)
13.8
(25.0)
14.2
(25.6)
14.4
(26.0)
14.4
(26.0)
14.5 G
(26.1)
14.5
(26.1)
BTU/ft hrF
(W/m K )
41.8 C
(72)
30 B
(51)
36 B
(62)
36 B
(62)
35 B
(60)
40 B G
(68)
40 B
(68)
Electrical Resistivity B
in.
( cm.)
Poissons Ratio
35.8
(14.1)
0.35
33.0
(13.0)
0.35
31.8
(12.5)
0.35
31.8
(12.5)
0.35
N/A
N/A
N/A
0.35
0.35
0.35
23
(160)
Compressive Yield Strength H

ksi
24
(165)
(MPa)
Elongation B
% in 2 in. (51mm)
Hardness F
BHN
Shear Strength B
ksi
(MPa)
Impact Strength D
ft-lb
(J)
Fatigue Strength A
ksi
(MPa)
Latent Heat of Fusion

Btu/lb
(kJ/kg)
Youngs Modulus B
psi x 10 6
(GPa)
n/a = data not available. A Rotating Beam fatigue test according to DIN 50113. Stress corresponding to a lifetime of 5 x 107 cycles. Higher values have been reported. These are conservative
values. Soundness of samples has great effect on fatigue properties resulting in disagreement among data sources. B At 68oF (20 oC). C At 212-572oF (100-300 oC). D ASTM E 23 unnotched
0.25 in. die cast bar. E 0.2% offset. F Average hardness based on scattered data. G Estimated. H 0.1% offset. Source: International Magnesium Assn.
* There are additional magnesium alloys that have been and are being developed for elevated temperature and creep resistant applications. See the data table on page 3-20. Contact your
alloy producer for more information.
3-22
Alloy Data
NADCA
A-3-12-15
GUIDELINES
considered in selecting a magnesium alloy for a specific application.
The benefits of consulting a custom die caster experienced in casting the magnesium alloy
being considered are clear.
Table A-3-12 Die Casting and Other Characteristics: Mg Alloys

Commercial:
Magnesium Die Casting

Alloys
AZ81
AM50A AM20 AE42

3G
3G
5G
4G
4G
2G
2G
1G
2G
1G
Resistance to Cold Defects a
Pressure Tightness
Resistance to Hot Cracking B
Machining Ease & Quality C
Electroplating Ease & Quality D
Surface Treatment E
Die-Filling Capacity
1G
Anti-Soldering to the Die
Corrosion Resistance
Polishing Ease & Quality
Chemical Oxide Protective Coating

Strength at Elevated Temperature
1G
1G
2G
1G
1G
2G
1G
1G
1G
2G
1G
1G
1G
1G
2G
1G
1G
1G
A The ability of alloy to resist formation of cold defects; for example, cold shuts, cold cracks, non-fill woody areas, swirls, etc.
B Ability of alloy to withstand stresses from contraction while cooling through the hot-short or brittle temperature range. C
Composite rating based on ease of cutting, chip characteristics, quality of finish and tool life. D Ability of the die casting to take and
hold on electroplate applied by present standard methods. E Ability of castings to be cleaned in standard pickle solutions and to be
conditioned for pest paint adhesion. F Rating based on resistance to creep at elevated temperatures. G Rating based upon limited
experience, giving guidance only. Sources: ASTM B94-92, International Magnesium Association.
* There are additional magnesium alloys that have been and are being developed for elevated temperature and creep resistant
applications. Contact your alloy producer for more information.
3-23
Alloy Data
Additional Magnesium Alloy Tensile Data
(Data is from separately cast specimens in as-cast condition)
Alloy
AE44-F
Temp F (C)
Tensile ksi (MPa)
Yield ksi (MPa)
Elong %
250 (121)
32 (160)
16 (112)
32.0
Room
29 (201)
27 (183)
1.7
257 (125)
28 (193)
21 (148)
6.0
302 (150)
26 (181)
20 (140)
6.6
356 (180)
24 (166)
20 (137)
8.6
Room
MRI 153M-F
MRI 230D-F
AJ52X-F
AS21X-F
AS31-F
AXJ530-F
35 (243)
20 (135)
8.3
Room
30 (206)
25 (172)
2.9
257 (125)
26 (177)
21 (144)
3.7
302 (150
24 (164)
20 (137)
3.2
356 (180)
22 (151)
19 (132)
3.0
Room
34 (234)
20 (136)
9.8
257 (125)
22 (155)
16 (110)
19.6
302 (150)
20 (141)
16 (107)
18.5
356 (180)
18 (125)
16 (112)
15.7
Room
31 (216)
18 (123)
10.1
257 (125)
19 (132)
13 (91)
30.6
302 (150)
17 (144)
12 (85)
26.3
356 (180)
14 (95)
11 (76)
26.4
Room
31 (212)
18 (127)
7.5
257 (125)
21 (148)
14 (98)
15.1
302 (150)
19 (131)
13 (93)
16.7
356 (180)
16 (108)
12 (84)
16.4
Room
31 (213)
22 (155)
3.9
257 (125)
25 (174)
19 (132)
4.4
302 (150)
23 (158)
18 (124)
4.4
356 (180)
20 (139)
17 (115)
4.8
The values in this table are average mean values and are provided for awareness of the new and emerging class of
creep-resistant magnesium alloys that are available. The properties shown do not represent design minimums and should be
used for reference only.
The property values in this table have been selected f rom data produced by the Structural Cast Magnesium Development (SCMD) Project and by the Magnesium Powertrain Cast Components (MPCC) Project of USAMP known as
AMD-111 and AMD-304 respectively. For information about these projects, please refer to USCAR http://www.uscar.
org or the DOE Energy Ef f iciency and Renewable Energy Vehicle Technologies Program http://www1.eere.energy.gov/
vehiclesandfuels/resources/fcvt_reports.htm.
Acknowledgement
This material is based upon work supported by the Department of Energy National Energy Technology Laboratory under
Award Nos. DE-FC05-95OR22363, DE-FC05-02OR22910, and DE-FC26-02OR22910.
This information was prepared as an account of work sponsored by an agency of the United States Government. Neither the
United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or
assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or
process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial
product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its
endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions
of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Such
support does not constitute an endorsement by the Department of Energy of the work or the views expressed herein.
3-24
Alloy Data
This page left blank intentionally.
3-25
Alloy Data
6
Zinc and ZA Alloys
Selecting Zinc and ZA Alloys

Zinc (Zn) alloy die castings offer a broad range of excellent physical and mechanical properties,
castability, and finishing characteristics. Thinner sections can be die cast in zinc alloy than in any
of the commonly used die casting alloys.
Zinc alloy generally allows for greater variation in section design and for the maintenance of
closer dimensional tolerances. The impact strength of zinc components is higher than other die
casting alloys, with the exception of brass. Due to the lower pressures and temperatures under
which zinc alloy is die cast, die life is significantly lengthened and die maintenance minimized.
This zinc alloy subsection presents guideline tables for chemical composition, typical
properties, and die casting, machining and finishing characteristics for the two groups of zinc
die casting alloys. This data can be used in combination with design engineering tolerancing
guidelines for zinc die casting and can be compared with the guidelines for other alloys in this
section and the Design Engineering section.
The zinc alloys include the traditional Zamak (acronym for zinc, aluminum, magnesium and
copper) group, Nos. 2, 3, 5, and 7, and the high-aluminum or ZA alloy group, ZA-8, ZA-12
and ZA-27.
The Zamak alloys all contain nominally 4% aluminum and a small amount of magnesium to
improve strength and hardness and to protect castings from intergranular corrosion. These alloys
all use the rapid-cycling hot-chamber process which allows maximum casting speed.
Miniature zinc die castings can be produced at high volume using special hot-chamber die
casting machines that yield castings which are flash-free, with zero draft and very close tolerances, requiring no secondary trimming or machining.
Zinc No. 3 is the most widely used zinc alloy in North America, offering the best combination
of mechanical properties, castability, and economics. It can produce castings with intricate detail
and excellent surface finish at high production rates. The other alloys in the Zamak group are
slightly more expensive and are used only where their specific properties are required
Alloys 2 and 5 have a higher copper content, which further strengthens and improves wear resistance, but at the expense of dimensional and property stability. No. 5 offers higher creep resistance
and somewhat lower ductility and is often preferred whenever these qualities are required. No. 7 is
a special high-purity alloy which has somewhat better fluidity and allows thinner walls to be cast.
The ZA alloys contain substantially more aluminum than the Zamak group, with the numerical designation representing the ZA alloys approximate percent Al content.
The higher aluminum and copper content of the ZA alloys give them several distinct
advantages over the traditional zinc alloys, including higher strength, superior wear resistance,
superior creep resistance and lower densities.
ZA-8, with a nominal aluminum content of 8.4%, is the only ZA alloy that can be cast by the
faster hot-chamber process. It has the highest strength of any hot-chamber zinc alloy, and the
highest creep strength of any zinc alloy.
ZA-12, with a nominal aluminum content of 11%, has properties that fall midway in the ZA
group. ZA-27, with a nominal aluminum content of 27%, has the highest melting point, the
highest strength, and the lowest density of the ZA alloys.
The machining characteristics of the Zamak and ZA alloys are considered very good.
High-quality surface finishes and good productivity are achieved when routine guidelines for
machining zinc are followed.

In many applications, zinc alloy die castings are used without any applied surface finish or treatment.
Differences in the polishing, electroplating, anodizing and chemical coating characteristics of
the Zamak and ZA alloys can be noted in table A-3-15.
3-26
Alloy Data
NADCA
A-3-13-15
STANDARD
Painting, chromating, phosphate coating and chrome plating can be used for decorative
finishes. Painting, chromating, anodizing, and iridite coatings can be used as corrosion barriers.
Hard chrome plating can be used to improve wear resistance, with the exception of ZA-27.
The bright chrome plating characteristics of the Zamak alloys and ZA-8 make these alloys a
prevailing choice for hardware applications.
A detailed discussion of finishing methods for zinc die castings can be found in Product
Design for Die Casting.
Table A-3-13 Chemical Composition: Zn Alloys
Commercial: ANSI/
AA
Nominal
Comp:
Zamak Die Casting Alloys C D
ZA Die Casting Alloys C D
No. 2
No. 3
AG-40A
No. 5
No. 7
AG-41A AG-40B
ZA-8
Al 4.0
Mg
0.035
Cu 3.0
Al 4.0
Mg 0.035
Al 4.0
Mg
0.055
Cu 1.0
Al 4.0
Mg 0.013
Cu 0.013
Al 8.4
Al 11.0
Mg 0.023 Mg
Cu 1.0
0.023
Cu 0.88
Al 27.0
Mg
0.015
Cu 2.25
3.7-4.3
3.7-4.3
8.0-8.8
25.0-28.0
0.005-0.020
0.010-0.030 0.010-0.030 0.010-0.020
ZA-12
ZA-27

Aluminum
3.7-4.3
3.7-4.3
Magnesium
0.02-0.06
0.02-0.06 A 0.02-0.06
Copper
2.6-3.3*
0.1 max B
0.70-1.20
0.1 max
0.8-1.3
0.5-1.2
2.0-2.5
Iron
0.05
0.05
0.05
0.005
0.075
0.075
0.075
Lead C
0.005
0.005
0.005
0.003
0.006
0.006
0.006
Cadmium C
0.004
0.004
0.004
0.002
0.006
0.006
0.006
Tin
0.002
0.002
0.002
0.001
0.003
0.003
0.003
Nickel
0.005-0.020
Zinc
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Al
Mg
Cu
Fe (max)
Pb (max)
Cd (max)
Sn (max)
Ni
Zn
10.5-11.5
A The magnesium may be as low as 0.015 percent provided that the lead, cadmium and tin do not exceed 0.003, 0.003 and 0.001
percent, respectively. B For the majority of commercial applications, a copper content of up to 0.7 percent will not adversely affect
the serviceability of die castings and should not serve as a basis for rejection. Sources: ASTM B86 and ASTM B791. C As specified,
the chemical composition of zinc and ZA alloys are in compliance with RoHS (the European Unions Directive on Restriction of
Hazardous Substances) If the presence of mercury is suspected, analysis shall be made to determine that the amount does not exceed 0.1
weight percent. Hexavalent chromium does not exist in the alloys and therefore meets the 0.1% limit. D Registration for REACH (the
European Unions Directive on Registration, Evaluation, and Authorization of Chemicals) is not required for die castings, even if
coated, since die castings are considered articles. Notification may be required if some contained substances in the die casting or coating
exceed the 0.1% total weight of the article level and are listed as SVHC (substances of very high concern).
Note: There are newly developed zinc alloys (a result of through NADCA sponsored research) for elevated temperature creep resistance
applications (such as ZCA-9). Contact your alloy producer for more information.
3-27
NADCA
Alloy Data
A-3-14-15
STANDARD
Table A-3-14 Typical Material Properties: Zn and ZA Alloys

Commercial:

for separately die cast specimens, not specimens
Zamak Die Casting Alloys
ZA Die Casting Alloys
No. 2
No. 3
No. 5
No. 7
AG-40A AG-41A AG-40B
ZA-8
ZA-12
ZA-27
41 (283)
35 (241)
48 (328)
39 (269)
41 (283)
41 (283)
54 (372)
43 (297)
59 (400)
45 (310)
62 (426)
52 (359)
32 (221)
39 (269)
32 (221)
41-43 (283-296) 45-48 (310-331) 52-55 (359-379)

32 (224)
35 (245)
46 (322)

As-Cast ksi (MPa)
52 (359)
48 (331)
Aged ksi (MPa)
Yield Strength a
As-Cast ksi (MPa)
41 (283)
Aged ksi (MPa)
Compressive Yield Strength B
As-Cast ksi (MPa)
93 (641)
93 (641)
Aged ksi (MPa)
Elongation
As-Cast % in 2 in.
7
(51mm)
2
Aged % in 2 in. (51mm)
Hardness D
As-Cast BHN
100
98
Aged BHN
Shear Strength
As-Cast ksi (MPa)
46 (317)
46 (317)
Aged ksi (MPa)
Impact Strength
As-Cast ft-lb
35
(47.5)
(J)
5
Aged ft-lb
Fatigue Strength F
As-Cast ksi (MPa)
8.5 (58.6)
8.5 (58.6)
Aged ksi (MPa)
Youngs Modulus
psi x 10 6
g
(GPa)
Density
lb/in 3
0.24
(6.6)
(g/cm3)
Melting Range
F
715-734
(379-390)
(C)
Specific Heat
BTU/lb F
0.10
(419)
(J/kg C)
m in/inF
15.4
(27.8)
(m m/mK)
BTU/ft hrF
60.5
(104.7)
(W/m K)
25.0
m in.
0.30
Poissons Ratio
60 (414) C 87 (600) C 60 (414) C

60 (414)
87 (600)
60 (414)
37 (252)
25 (172)
39 (269)
27 (186)
52 (358)
37 (255)
10
16
7
13
13
18
6-10
20
4-7
10
2.0-3.5
3
82
72
91
80
80
67
100-106
91
95-105
91
116-122
100
31 (214)
31 (214)
38 (262)
38 (262)
31 (214)
31 (214)
40 (275)
33 (228)
43 (296)
33 (228)
47 (325)
37 (255)
43 E
(58)
41
48 E
(65)
40
43 E
(58)
41
24-35 E
(32-48)
13
15-27 E
(20-37)
14
7-12 E
(9-16)
3.5
6.9 (47.6)
6.9 (47.6)
8.2 (56.5)
8.2 (56.5)
6.9 (47.6)
6.8 (46.9)
15 (103)
15 (103)
21 (145)
21 (145)
12.4
(85.5)
12
(83)
11.3
(77.9)
0.24
(6.6)
0.24
(6.6)
0.24
(6.6)
0.227
(6.3)
0.218
(6.03)
0.181
(5.000)
718-728
(381-387)
717-727
(380-386)
718-728
(381-387)
707-759
(375-404)
710-810
(377-432)
708-903
(372-484)
0.10
(419)
0.10
(419)
0.10
(419)
0.104
(435)
0.107
(450)
0.125
(525)
15.2
(27.4)
15.2
(27.4)
15.2
(27.4)
12.9
(23.2)
13.4
(24.1)
14.4
(26.0)
65.3
(113)
62.9
(109)
65.3
(113)
66.3
(115)
67.1
(116)
72.5
(122.5)
27.0
0.30
26.0
0.30
27.0
0.30
27.7
0.30
28.3
0.30
29.7
0.30
a 0.2% offset, strain rate sensitive, values obtained at a strain rate of 0.125/min (12.5% per minute). B 0.1% offset. C Compressive strength. D 500 kg load, 10
mm ball. E ASTM 23 unnotched 0.25 in. die cast bar. F Rotary Bend 5 x 108 cycles. G Varies with stress level; applicable only for short-duration loads. Use 107
as a first approximation. Source: International Lead Zinc Research Organization.
3-28
Alloy Data
NADCA
A-3-15-15
GUIDELINES
considered in selecting a zinc alloy for a specific application.
The benefits of consulting a custom die caster experienced in casting the zinc alloy being
Table A-3-15 Die Casting and Other Characteristics: Zn and ZA Alloys

Commercial: ANSI/AA
Zamak Die Casting Alloys

No. 2
No. 3
AG-40A
No. 5
No. 7
AG-41A AG-40B
ZA-8
ZA-12
ZA-27
Resistance to Hot Cracking B
Pressure Tightness
Casting Ease
Part Complexity
Machining Ease & Quality C
Polishing Ease & Quality
Electroplating Ease & Quality D
Anodizing (Protection)
Dimensional Accuracy
Dimensional Stability
Resistance to Cold Defects A
Chemical Coating (Protection)
A The ability of alloy to resist formation of cold defects; for example, cold shuts, cold cracks, non-fill woody areas, swirls, etc. B Ability of alloy to
withstand stresses from contraction while cooling through the hot-short or brittle temperature range. C Composite rating based on ease of cutting. Chip
characteristics, quality of finish and tool life. D Ability of the die casting to take and hold an electroplate applied by present standard methods. Source:
International Lead Zinc Research Organization.
3-29
Alloy Data
Zinc HF Alloy Typical Properties
Zinc HF Alloy Chemical Composition
Mechanical Proper ties
Detailed Composition
(A)
As-Cast ksi (MPa)
40 (276)
Aged ksi (MPa)
34 (234)
Yield Strength
As-Cast ksi (MPa)
35 (241)
Aged ksi (MPa)
29 (200)
Elongation
As-Cast % in 2 in. (51mm)

Aged % in 2 in. (51mm)
Hardness (B)
As-Cast BHN
Aged BHN
Impact Strength
5.3
9.9
Aged ft-lb ( J)
psi x 106
Lead Pb
0.003 max
Tin Sn
0.001 max
Cadmium Cd
Nickel Ni
Zinc Zn
0.002 max
-
Remainder
(C) - Sample dimensions 0.25 x 0.25 x 3 in.

(D) - Calculated using stress-strain curve
(E) - Based on published data for Alloy 7
Note: Samples as-cast were tested at 68 F (20 C).
Samples aged were kept at 203 F (95 C) for 10 days.
Density
lb/in3
0.239
(g/cm3)
6.602
Melting Range
F
716-723
(C)
380-384
Specific Heat
BTU/lb F at 68-212 F
( J/kg C) at 20-100 C
m in/inF at 68-212 F
(m m/mK) at 20-100 C
0.1
403
16.5
26.2
(E)
BTU/ft hrF at 158-252 F
113
Poissons Ratio
0.30
(W/m K) at 70-140 C
Solidification Shrinkage (in/in)
3-30
0.03 max
0.03 nominal
(B) - Tested under 250 kg weight with 5 mm ball
Physical Properties
Iron Fe
Copper Cu
28 (38)
91.7
0.01 nominal
71
13.3
(GPa)
Magnesium Mg
(A) - Sample cross-section dimensions 0.040 x 0.500 in.;

tensile strength increased to 54 ksi when sample crosssection was reduced to 0.020 x 0.300 in.
21 (28)
Youngs Modulus (D)
4.3-4.7
93
(C)
As-Cast ft-lb ( J)
Aluminum Al
65.3
0.0117
Alloy Data
3-31
Alloy Data
7
Selecting An Alloy Family
Overview
Although this product specification standards document addresses copper and metal matrix
composites (MMC), the four main alloy families are Aluminum, Zinc, Magnesium, and
Zinc-Aluminum. This subsection is presented to assist in selecting an alloy family, which is the
precursor to selecting a specific alloy within a family. Information on selecting the specific alloys
is presented at the beginning of each alloy family subsection.
Typical considerations in selecting an alloy family include; alloy cost and weight, die casting
process cost, structural properties, surface finish, corrosion resistance, bearing properties and corrosion resistance, machinability, thermal properties, and shielding (EMI/electrical conductivity).
Cost & Weight

Alloy cost and weight is an important factor in the overall product cost, therefore the amount or
volume of material used should be taken into consideration. Aluminum alloys usually yield the
lowest cost per unit volume. Magnesium and zinc can be competitive because they can generally
be cast with thinner walls, thereby reducing the volume of alloy needed. If weight minimization
is the over-riding factor, magnesium alloys are the choice to make. It should be noted that zinc
alloys have a distinct advantage in the production of miniature parts and may be the dominant
choice if the casting configuration is of a very small size.
Another important component of the overall product cost is the die casting process. Alloys
produced by the hot chamber process such as magnesium and much of the zinc are typically run
in smaller die casting machines and at higher production rates then those produced by the cold
chamber process such as aluminum and zinc-aluminum.
Production tooling maintenance and replacement costs can be significant. Tooling for zinc
generally lasts longer than aluminum and magnesium tooling. This is due primarily to the higher
casting temperatures of aluminum and magnesium.
Structural Properties
Each alloy has a unique set of properties. However, if one is in search of one or two properties
that are most important for a specific design or interested in which properties are characteristic
of an alloy family, the following generalizations may be helpful. Aluminum alloys yield the highest modulus of elasticity. Magnesium alloys offer the highest strength-to-weight ratio and the
best dampening characteristics. The zinc alloys offer the highest ductility and impact strength.
The ZA alloys offer the highest tensile and yield strength.
Surface Finish and Coatings

Whether a high surface finish is for functional or aesthetic reasons, it is often a requirement. Ascast surface finishes are best achieved with zinc and magnesium alloys. Zinc alloys most readily
accept electro-coatings and decorative finishes. The relatively higher temperature resistance of
the aluminum alloys makes them best suited for elevated temperature coating processes.
Corrosion resistance varies from alloy family to alloy family and within an alloy family. If
corrosion resistance is a concern, it can be improved with surface treatments and coatings. Refer
to the information on selecting specific alloys at the beginning of each alloy family subsection to
see which specific alloys yield higher corrosion resistance.
Bearing Properties and Wear Resistance

The ZA alloys and some of the aluminum alloys are more resistant to abrasion and wear than
the other die casting alloys. As for corrosion resistance, abrasion and wear resistance can be
improved with surface treatments and coatings.
3-32
Alloy Data
Machinability
Even though die castings can be produced to net or near-net shape, machining is often required.
When required, machining is easily accomplished on all of the die casting alloys. Magnesium,
however offers the best machinability in terms of tool life, achievable finish, low cutting forces and
energy consumption.
Thermal Properties and Shielding

Aluminum alloys are typically the best choice for heat transfer applications with zinc alloys as a
close second. Aluminum and zinc alloys are top choices for electrical conductivity. Of the die casting
alloys, magnesium alloys offer the best shielding of electromagnetic emissions.
Quick Guide to Alloy Family Selection

A luminum
Lowest cost per

unit volume.
Cost
Second lowest in
density next to
magnesium.
Weight
High Modules
of Elasticity
Structural
Properties
Good choice for

coating processes
that require high
temperatures.
Surface Finish
& Coatings
Mag nesium
Effective production of
miniature parts. Significant
long-term tooling cost
savings (tooling lasts up
to 10 times longer than
aluminum).
Highest strength-toweight ration, best

vibration dampening
characteristics.
Highest ductility and impact Highest tensile and

strength.
yield strength. High
Modules of Elasticity
Lowest density.
Good as-cast
surface finishes can be
achieved.
*
*
Good
Machinability
Thermal
Properties,
Conductive, &
Electromagnetic
Shielding
Best choice for

heat transfer
Good electrical
conductivity
Electromagnetic
shielding
Zinc-A luminum
Can compete with

aluminum if thinner
wall sections are used.
Faster hot-chamber
process possible on
smaller parts.
Wear Resistance *
Corrosion
Resistance
Zinc
Heaviest of die cast alloys,

but castable with thinner
walls than aluminum,
which can offset the weight
disadvantage.
Best as-cast surface finish

readily accepts electrocoatings and decorative
finishes.
Weight reduction as
compared with the
Zinc family of alloys.
Best as-cast wear resist.
Best machinability
in terms of tool-life,
achievable finish, low
cutting forces and
energy consumption.
Good
Good
Best electrical conductor.

Good heat transfer
Electromagnetic shielding
Electromagnetic
shielding
Electromagnetic
shielding
* Wear and corrosion resistance can be improved in all alloys through surface treatments and coatings.
3-33
Alloy Data
9
Elevated Temperature Properties
Elevated Temperature Properties of Aluminum

Alloy
Temp F (C) Tensile ksi (MPa) Yield ksi (MPa)
360
A360
380
A380
-112 (-80)
-18 (-26)
68 (20)
212 (100)
300 (150)
400 (205)
500 (260)
600 (315)
700 (370)
Elong %
-112 (-80)
-18 (-26)
68 (20)
212 (100)
300 (150)
400 (205)
500 (260)
600 (315)
700 (370)
50 (345)
48 (330)
44 (303)
44 (303)
35 (241)
22 (152)
12 (83)
7 (48)
4.5 (31)
25 (172)
25 (172)
25 (172)
25 (172)
24 (166)
14 (97)
7.5 (52)
4.5 (31)
3 (21)
2
2
2.5
2.5
4
8
20
35
40
46 (317)
43 (296)
34 (234)
21 (145)
11 (76)
6.5 (45)
4 (30)
24 (166)
24 (166)
23 (159)
13 (90)
6.5 (45)
4 (28)
2.5 (15)
-112 (-80)
-18 (-26)
68 (20)
212 (100)
300 (150)
400 (205)
500 (260)
600 (315)
23 (159)
23 (159)
23 (159)
24 (166)
22 (152)
16 (110)
8 (55)
4 (28)
2.5 (17)
3.5
3.5
5
14
30
45
45
2.5
3
3.5
4
5
8
20
30
35
47 (324)
44 (303)
33 (228)
23 (159)
12 (83)
6 (41)
23 (159)
23 (159)
21 (145)
15 (103)
7 (48)
6 (41)
3.5
5
10
15
30
45
-112 (-80)
-18 (-26)
68 (20)
212 (100)
300 (150)
400 (205)
500 (260)
600 (315)
700 (370)
49 (338)
49 (338)
46 (317)
45 (310)
34 (234)
24 (165)
13 (90)
7 (48)
4 (28)
The values in this table are from various sources and represent typical values. These values do not represent design minimums
and should be used for reference only.
3-34
Alloy Data
Elevated Temperature Properties of Aluminum
Alloy
Temp F (C) Tensile ksi (MPa) Yield ksi (MPa)
384
-112 (-80)
-18 (-26)
68 (20)
212 (100)
300 (150)
400 (205)
500 (260)
600 (315)
Elong %
48 (330)
44 (303)
38 (262)
26 (179)
14 (97)
7 (48)
24 (165)
24 (165)
24 (165)
18 (124)
9 (62)
4 (28)
2.5
2.5
5
6
25
45
46 (317)
41 (283)
36 (250)
27 (186)
<1
1
-112 (-80)
390
-18 (-26)
68 (20)
212 (100)
300 (150)
400 (205)
500 (260)
600 (315)
-112 (-80)
13
-112 (-80)
45 (310)
21 (145)
32 (221)
19 (131)
400 (205)
300 (150)
1
1
19 (131)
44 (303)
42 (290)
37 (255)
600 (315)
21 (145)
19 (131)
19 (131)
2
3.5
5
24 (166)
15 (103)
15
7 (48)
5 (34)
35
35 (241)
16 (110)
12
22 (152)
14 (97)
10
13 (90)
9 (62)
29
35 (241)
33 (228)
28 (193)
400 (205)
16 (110)
12 (83)
600 (315)
5 (34)
4 (28)
6 (41)
30
-112 (-80)
51 (352)
29 (200)
14
32 (221)
21 (145)
300 (150)
9 (62)
16 (110)
14 (97)
14 (97)
-18 (-26)
68 (20)
212 (100)
500 (260)
218
29 (200)
-18 (-26)
68 (20)
212 (100)
500 (260)
43
37 (255)
25
35
-18 (-26)
68 (20)
212 (100)
50 (345)
44 (310)
40 (276)
400 (205)
21 (145)
15 (104)
40
9 (62)
5 (34)
46
300 (150)
500 (260)
600 (315)
13 (90)
29 (200)
28 (193)
25 (172)
13
9
9
9 (62)
10
5
8
25
45
The values in this table are from various sources and represent typical values. These values do not represent design minimums
3-35
Alloy Data
Impact Strength of Aluminum A380 Die Casting Alloy as a Function of Temperature
Temperature (C)
Impact Strength (ft-lb)
Standard Deviation
-190
4.47
0.92
-100
4.92
0.80
-50
5.20
0.90
5.66
0.93
25
5.91
0.95
100
6.43
0.89
150
6.66
0.94
240
6.83
0.88
The values in this table are from various sources and represent typical values. These values do not represent design minimums and should
be used for reference only.
A380 Impact Strength at Temperature
3-36
Alloy Data
Elevated Temperature Properties of Zinc
Alloy
Temp F (C)
Tensile ksi (MPa)
-40 (-40)
56.0 (386)
54.5 (376)
32 (0)
53.2 (367)
50.3 (347)
-4 (-20)
72 (22)
167 (75)
275 (135)
-40 (-40)
34.1 (235)
15.8 (109)
46.3 (319)
28.0 (193)
11.9 (82)
32 (0)
43.4 (299)
37.0 (255)
167 (75)
26.0 (179)
22.0 (152)
72 (22)
47.4 (327)
39.3 (271)
11.7 (81)
33.6 (232)
10.4 (72)
54.2 (374)
47.6 (328)
32 (0)
48.3 (333)
44.2 (305)
72 (22)
167 (75)
275 (135)
51.8 (357)
45.0 (310)
30.3 (209)
11.7 (81)
46.1 (318)
41.9 (289)
26.0 (179)
11.5 (79)
-40 (-40)
64.0 (441)
54.1 (373)
32 (0)
55.5 (383)
47.6 (328)
-4 (-20)
72 (22)
167 (75)
275 (135)
59.8 (412)
50.5 (348)
29.9 (206)
11.6 (80)
39.0 (269)
-40 (-40)
-4 (-20)
49.7 (343)
54.8 (378)
40.0 (276)
275 (135)
57.9 (399)
49.2 (339)
-4 (-20)
Yield ksi (MPa)
50.8 (350)
41.2 (284)
22.3 (154)
9.6 (66)
The values in this table are from Omer Dogan and Karol Schrems, Determination of Mechanical Properties of Die Cast Zinc
Alloys for Automotive Applications, Final Report, prepared for International Lead Zinc Research Organization, NETL-ATR-2007-08, work performed under CR ADA 05-05 ILZRO, March 2007.. These values do not represent design minimums
Zinc Tensil Strength at Temperature
Zinc Yield Strength at Temperature
3-37
Alloy Data
10
Property Comparison
Compet it ive Per for ma nce Cha r t
Alloy Property
ZAMAK
3**
ZAMAK
5**
ZA-8***
ZA-12***
ZA-27***
Die
Cast
Die
Cast
Sand
Cast
Perm
Mold
Die
Cast
Sand
Cast
Perm
Mold
Die
Cast
Sand
Cast
Perm
Mold
41
(283)
48
(331)
38
(263)
35
(240)
54
(374)
43
(299)
48
(328)
59
(404)
61
(421)
64
(441)
32
(221)
33
(228)
29
(198)
30
(208)
42
(290)
31
(211)
39
(268)
46
(320)
54
(371)
55
(376)
10
1.7
1.3
1.5
2.2
4.6
2.5
12.4
(85.5)
12.4
(85.5)
12.4
(85.5)
12.0
(82.7)
12.0
(82.7)
12.0
(82.7)
11.3
(77.9)
11.3
(77.9)
Mec ha n ica l Proper t ies

psi x103
(MPa)
Yield Strength
psi x103
(MPa)
Elongation
% in 2in.
Youngs Modulus
psi x10 6
(MPa x 103)
Torsional Modulus
psi x10 6
(MPa x 103)
Shear Strength
psi x103
(MPa)
> 12.4**** > 12.4****

(> 85.5)
(> 85.5)
> 4.8
(> 33.1)
> 4.8
(> 33.1)
4.8
(33.1)
4.8
(33.1)
4.8
(33.1)
4.6
(31.7)
4.6
(31.7)
4.6
(31.7)
4.3
(29.6)
4.3
(29.6)
31
(214)
38
(262)
N/A
35
(241)
40
(275)
37
(253)
> 35
(>241)
43
(296)
42
(292)
N/A
82
91
85
87
103
94
89
100
113
114
43
(58)
48
(65)
15
(20)
N/A
31
(42)
19
(25)
N/A
21
(29)
35
(48)
N/A
N/A
7.5
(57.1)
15
(103)
15
(103)
N/A
17
(117)
25
(172)
N/A
29
(199)
31
(210)
37
(252)
33
(230)
34
(235)
39
(269)
48
(330)
N/A
Hardness
(Brinell)
Impact Strength
ft-lb
(J)
Fatigue Strength Rotoary Bedn (5 x 10 6 cycles)

psi x103
(MPa)
6.9
(47.6)
8.2
(56.5)
Compressive Yield Strength 0.1% Offset

psi x103
(MPa)
60
(414)
87
(600)
* Minimum Properties
** Complies with ASTM specification B86.
*** Complies with ASTM specification B669.
**** Varies with stress level; applicable only for shot-duration loads.
3-38
Alloy Data
Aluminum
Magnesium
Iron
Plastic
380
319
356-T6
713 -F*
6061-T6
AZ91D
AM60B
Class 30
32510
Die
Cast
Die
Cast
Sand
Cast
Sand
Cast
Sand
Cast
Wrought
Die
Cast
Die
Cast
Gray Cast
Iron
Malleable
Iron
ABS
62
(426)
47
(324)
27
(186)
33
(228)
32
(220)
45
(310)
34
(234)
32
(220)
31
(214)
50
(345)
54
(371)
24
(165)
18
(124)
24
(165)
22
(150)
40
(276)
23
(159)
19
(130)
18
(124)
32
(221)
2.5
3.0
3.5
17
nil
10
11.3
(77.9)
10.3
(71.0)
10.7
(73.8)
10.5
(72.4)
6.5
(44.8)
6.5
(44.8)
13-16
(89.6)
25
(172.4)
4.3
(29.6)
3.9
(26.9)
4.0
(27.6)
3.9
(26.9)
2.4
(16.5)
N/A
N/A
9.3
(64.1)
47
(325)
27
(186)
22
(152)
26
(179)
30
()
20
(138)
N/A
43
296
45
(310)
119
80
70
70
60-90
95
63
62
170-269
110-156
9
(13)
3
(4)
4
(5)
8
(11)
2.7
(3.7)
5
(6)
nil
40-65
(54-88)
21
(145)
20
(138)
10
(69)
8.5
(58.6)
14
()
14
(97)
10
(70)
14
(97)
28
(193)
52
(359)
N/A
19
(131)
25
(172)
23
(159)
19
(130)
109
(752)
N/A
Nylon 6
(30%
Glass
Filled)
22
7
1
1.5
0.15
0.3
3-39
Alloy Data
Compet it ive Per for ma nce Cha r t
Alloy Property
ZAMAK
3**
ZAMAK
5**
ZA-8***
ZA-12***
ZA-27***
Die
Cast
Die
Cast
Sand
Cast
Perm
Mold
Die
Cast
Sand
Cast
Perm
Mold
Die Cast
Sand
Cast
Perm
Mold
0.24
(6600)
0.24
(6600)
0.227
(6300)
0.227
(6300)
0.227
(6300)
0.218
(6030)
0.218
(6030)
0.218
(6030)
0.181
(5000)
0.181
(5000)

Density
lb/in 3
(Kg/m 3)
Melting Range
F
(C)
718-728
717-727
(381-387) (380-386)
% IACS
26
27.7
27.7
27.7
28.3
28.3
28.3
29.7
29.7
65.3
(113.0)
62.9
(108.9)
66.3
(114.7)
66.3
(114.7)
66.3
(114.7)
67.1
(116.1)
67.1
(116.1)
67.1
(116.1)
72.5
(125.5)
72.5
(125.5)

1/F x 10 -6
(1/C x 10 -6)
Pattern Shrinkage
in/in or mm/mm
3-40
708-903
(376-484)
27
BTU/ft hrF
(W/m K)
707-759 707-759
707-759 710-810 710-810 710-810 708-903
(375(375(375-404) (377-432) (377-432) (377-432) (376-484)
404)
404)
15.2
(27.4)
15.2
(27.4)
12.9
(23.3)
12.9
(23.3)
12.9
23.3)
13.4
(24.2)
13.4
(24.2)
13.4
(24.2)
14.4
(26.0)
14.4
(26.0)
0.006
0.006
0.010
0.010
0.007
0.013
0.013
0.0075
0.013
0.013
Alloy Data
Aluminum
Magnesium
Iron
380
319
356-T6
713 -F*
6061-T6
AZ91D
AM60B
Class 30
32510
Die
Cast
Die
Cast
Sand
Cast
Sand
Cast
Sand
Cast
Wrought
Die
Cast
Die
Cast
Gray Cast
Iron
Malleable
Iron
0.181
(5000)
0.098
(2713)
0.101
(2796)
0.097
(2685)
0.100
()
0.066
(1827)
0.065
(1790)
0.25
(6920)
0.26
(7198)
>2150
(>1177)
>2250
(>1232)
708-903
(376-484)
1000- 960-1120
1035-1135 1100-1180 1080-1205 875-1105 1005-1140
1100
(516(557-613) (593-638)
()
(468-596) (540-615)
(538-593) 604)
29.7
27
27
39
30
43
11.5
N/A
N/A
72.5
(125.5)
55.6
(96.2)
65.5
(113.4)
87
(151)
97
(168)
41.8
(72.3)
36
(62)
28-30
(48-52)
N/A
14.4
(26.0)
11.8
(21.2)
11.9
(21.4)
11.9
(21.4)
13.4
(24.2)
13.1
(23.7)
14
(25.2)
14.2
(25.6)
6.7
(12.1)
6.6
(11.9)
0.008
0.006
N/A
N/A
N/A
N/A
0.010
0.010
3-41
Alloy Data
11
Cross Reference: Alloy Designations and Alloy Compositions
SG 100B 360
JIS
H5302
ADC3
A360 AO3602
309
SG 100A 360
GDAlSi10Mg
AlSi10Mg
EN
AC-43400
YL104
AO3801 306.308
SC84AB
380
143
JIS
H5302
ADC10
A380 AO3802 306.308
SC84-A
380
LM24
GDAlSi8Cu
Al-Si8Cu3Fe
EN
AC-46500
YL112
LM2
JIS
H5302
ADC12
380
Japan
China
A380
E N 17 0 6
380
ISO
A360
Germany
309
United
K ingdom
SAE
AO3601
Canada
U NS
Unif ied
No. System
360
Q Q -A-3 7 1c .
Fo r m e r
Desig nation
360
Old A STM
A NSI
ASTM or
A A Number
Cross Reference of Equ iva lent A luminum A l loy Specif icat ions a nd Desig nat ions
EN
YL113
AC-46100
383
383
AO3831 306.308
384
384
AO3841
313
SC114A
384 A143 LM26
A384 AO3842
303
SC114A
384
A384
390
AO3902
LM28
B390
AO3901
413
13
AO4131
305
S12A.B
13
162
LM6
JIS
H5302
ADC1
A413
A13
A14132
305
S12A
13
AlSi12CuFe
443
43
AO4431
35
S5B
43
123
LM18
518
218
AO5181
218
340
3-42
EN
YL108
AC-47100
Alloy Data
Inter nat iona l A luminum A l loy Composit ions
J A PA N
JIS H5302 ADC1
JIS H5302 ADC3
JIS H5302 ADC10
JIS H5302 ADC12
Cu
Mg
0.6
0.4-0.6
1.5-3.5
0.3
9.6-12.0
Mg
Si
1.0
2.0-4.0
U NITED K INGDOM
LM2
B.S.1490
LM6
LM18
LM24
LM26
GER M A N Y
GD-Al-Si8Cu3
GD-Al-Si10Mg
ISO
Al-Si8Cu3Fe
Al-Si10Mg
Cu
0.3
0.3
0.7-2.5
0.30
0.1
0.10
0.1
3.0-4.0
0.10
0.30
Si
1.3
0.3
7.5-9.5
1.3
9.0-10.0
9.0-11.5
10.0-13.0
4.5-6.0
7.5-9.5
1.3
1.3
8.5-10.5
1.2
Cu
Mg
Si
Fe
2.0-3.5
0-0.3
7.5-9.5
0.10
0.20-0.50
9.0-11.0
Cu
Mg
Si
2.5-4.0
0.3 max
7.5-9.5
0.1
max
0.15-0.40
9.0-11.0
EN AC-43400
0.1
EN AC-46100
1.5-2.5
EN AC-47100
0.7-1.2
2.0-4.0
Mg
0.200.50
Si
0.1
0.1
0.2
Mn
Ni
Zn
Pb
0.1
0-0.4
0.6
max
0.6
max
0.05
max
Mn
Pb
0.3
max
Ti
Others
0.2
0.2
0.05
0.2
0.2
Sn
0.1
Sn
Ti
Each
Total
0.15
0.05
0.15
0.15
0.05
Ti
0.2
max
0.2
max
0.15
Each
0.5 max
0.1
max
0.05
max
0.05
max
0.2
max
Ni
Zn
Pb
Sn
Ti
Each*
Total*
0.15
0.15
0.15
0.05
0.20
0.3
10.0-12.0
1.1
0.55
0.45
1.7
0.25
0.15
0.25
0.05
0.25
0.35
10.5-13.5
1.3
0.55
0.30
0.55
0.20
0.10
0.20
0.05
0.25
0.05-0.55 8.0-11.0
Mg
Si
1.3
Fe
0.55
Mn
Ni
0.3-0.9
0.05
0.5
0.5
1.0
0.2-0.5
YZA1Si9Cu4
3-4
0.3
7.5-9.5
1.2
0.5
0.4--1
0.3
11-13
9.6-12
1.0
1.2
0.55
3.0
Zn
0.35
Pb
0.15
0.25
0.01
0.05
0.01
0.5
1.2
0.1
0.1
1.0
0.05
0.1
0.25
Ti
0.3
1.0
0.05
Sn
0.1
0.2
0.1
0.55
8-10.5
1.5-3.5
Zn
1.2
max
1.0
0.17--0.3
YZA1Si11Cu3
Ni
0.5
max
0.2
0.2
0.2
0.2
0.3
0.3
0.1
0.7
0.05
0.5
0.3
0.3
0.1
0.5
0.5
Sn
0.1
0.1
0.1
Pb
0.5
0.1
Total
0.3
0.3
0.3
1-2
Zn
Each
2.0
YZA1Si10Mg
YZA1Si12Cu2
Ni
1.0
0.5
Mn
Fe
0.5
Ti
0.1
0.5
Fe
0.6
max
0.5
Sn
9.0-11.0
AC=Component cast in aluminum *=other trace elements
Cu
1.0
0.2-0.5
1.3
max
0.5
0.3
1.3
1.0
0.5
0.3
0.5
0.5-1.5
Pb
0.5
0.6
0.6
Zn
0.5
Mn
1.0
Ni
0.3
Fe
2.0-4.0
Cu
China
Mn
1.3
E U R O P E A N S TA N D A R D E N 17 0 6
EN AC-46500
Fe
11.0-13.0
3-43
Alloy Data
C RO S S R E F E R E N C E O F E Q U I VA L E N T M AG N E S I U M
A L L O Y S P E C I F I C AT IO N S A N D D E S I G N AT IO N S
U.S.A STM
ISO 16220
EN-1753/1997
AZ91D
MgAl9Zn1
AZ91
AM60B
MgAl6Mn
AM60
AM50A
MgAl5Mn
AM50
AM20
MgAl2Mn
AM20
AS21
MgAl2Si
AS21
AS41B
MgAl4Si
AS41
Inter nat iona l Mag nesium A l loy Composit ion

U. S.
ASTM
%Al
%Zn
%Mn
% Fe
%Cu
%Ni
0.10
0.005
0.030
0.002
0
Each
Fe / M n
Ma x.
0.021**
AZ91D
8.3-9.7
AM60B
5.5-6.5
0.22
0.24-0.6
0.10
0.005
0.010
0.002
0.02
AM50A
4.4-5.4
0.22
0.26-0.6
0.10
0.004
0.010
0.002
0.02
AM20
AS21
3.5-5.0
0.12
0.0065
0.02
0.002
0.02
0.010**
AS41B
ISO 16220
0.35-1.0 0.15-0.50
%Si
0.35-0.7 0.50-1.5
0.01
0.032***
0.015**
MgAl9Zn1
8.3-9.7
0.35-1.0 0.15-0.50
0.10
0.005
0.030
0.002
0.01
0.032**
MgAl6Mn
5.5-6.5
0.2 0.2
0.24-0.60
0.10
0.005
0.010
0.002
0.01
0.021*
MgAl5Mn
4.4-5.5
0.2
0.26-0.60
0.10
0.004
0.010
0.002
0.01
0.015*
MgAl2Mn
1.6-2.6
0.2
0.33-0.70
0.10
0.004
0.010
0.002
0.01
0.012*
MgAl2Si
1.8-2.6
0.2
0.18-0.70
0.7-1.2
0.004
0.010
0.002
0.01
0.022*
MgAl4Si
3.5-5.0
0.2
0.18-0.70 0.5-1.5a
0.004
0.010
0.002
0.01
0.022*
0.10
0.005
0.030
0.002
0.01
EN-1753/1997
3-44
AZ91
8.3-9.7
0.35-1.0 min. 0.1
AM60
5.5-6.5
0.2
min. 0.1
0.10
0.005
0.010
0.002
0.01
AM50
4.4-5.5
0.2
min. 0.1
0.10
0.005
0.010
0.002
0.01
AM20
1.6-2.6
0.2
min. 0.1
0.10
0.005
0.010
0.002
0.01
AS21
1.8-2.6
0.2
min. 0.1
0.7-1.2
0.005
0.010
0.002
0.01
AS41
3.5-5.0
0.2
min. 0.1
0.50-1.5
0.005
0.010
0.002
0.01
Alloy Data
U.S.
Commercial
Cross Reference of Equivalent Zinc Alloy Specifications and Designations

United
Kingdom
Japan
Germany
ISO
EN
UNS
ZP0430
ZnAl4Cu3
Z35541
AG40
Class 2
Z400
ZP0400
ZnAl4
Z33521
905
Class 1
Z410
ZP0410
ZnAl4Cu1
Z35531
ZA8
ZP0810
ZnAl8Cu1
Z35636
ZA-12
ZA12
ZP1110
ZnAl11Cu1
Z35631
ZA-27
ZA27
ZP2720
ZnAl27Cu2
Z35841
ASTM
SAE
Canada
#2
AC43A
#3
AG40A
903
#5
AC41A
ZA-8
EN 12844
% Al
% Cu
ZnAl4-P
3.7-4.3
ZnAl4Cu1-P
3.7-4.3
International Zinc Alloy Composition

% Mg
% Pb
% Cd
% Sn
% Fe
% Ni
% Si
0.1
0.025-0.06
0.005
0.005
0.002
0.05
0.02
0.03
0.7-1.3
0.4-0.6
0.005
0.005
0.002
0.05
0.02
0.03
Chemical Composition of Zinc Alloy Castings

Short
Designation
% Al
% Cu
% Mg
% Pb
% Cd
% Sn
% Fe
ZP0430
ZP2
3.7-4.3
2.6-3.3
.02-.06
.005
.004
.002
.05
ZP0400
ZP3
3.7-4.3
.1
.02-.06
.005
.004
.002
.05
ZP0410
ZP5
3.7-4.3
.7-1.2
.02-.06
.005
.004
.002
.05
ZP0810
ZP8
8.0-8.8
.8-1.3
.01-.03
.006
.006
.003
.075
ZP1110
ZP12
10.5-11.5
.5-1.2
.01-.03
.006
.006
.003
.075
ZP2720
ZP27
25.0-28.0
2.0-2.5
.01-.02
.006
.006
.003
.075
ISO 15201
3-45
Alloy Data
3-46

Section Contents
NADCA No.
Format
section
Page
4A-2
1 Introduction
4A-2
2 Section Objectives
4A-3
3 Standard and Precision Tolerances
4A-3
4 Production Part Technologies
4A-4
5 Die Casting, SSM & Squeeze Cast Part Design
4A-6
6 Linear Dimensions Tolerances
7 Parting Line Tolerances
8 Moving Die Component Tolerances
9 Angularity Tolerances
S-4A-1-15
Standard
4A-7
P-4A-1-15
Precision
4A-8
S-4A-2-15
Standard
4A-9
P-4A-2-15
Precision
4A-10
S-4A-3-15
Standard
4A-11
P-4A-3-15
Precision
4A-12
S-4A-5-15
Standard
4A-17
11 Parting Line Shift
S-4A-6-15
Standard
4A-19
12 Draft Tolerances
S-4A-7-15
Standard
4A-21
P-4A-7-15
Precision
4A-23
S-4A-8-15
Standard
4A-29
P-4A-8-15
Precision
4A-30
14 Design Recommendations:
Cored Holes As-Cast
15 Cored Holes for Cut Threads
4A-31
S-4A-9-15
Standard
4A-34
P-4A-9-15
Precision
4A-35
16 Cored Holes for Formed Threads
P-4A-10-15
Precision
4A-36
17 Cored Holes for Pipe Threads
S-4A-11-15
Standard
4A-38
18 Cast Threads
S-4A-12-15
Standard
4A-39
19 Machining Stock Allowance
4A
S/P-4A-4-15 Standard/Precision 4A-13
10 Concentricity Tolerances
13 Flatness Tolerances
4A
S/P-4A-13-15 Standard/Precision 4A-40
20 Additional Considerations for Large Castings
4A-42
4A-1

Tolerance in any part is a
three-dimensional characteristic. Many different
types of tolerance will
be discussed throughout
sections 4A and 4B. Most
feature tolerances will
have Linear Tolerance in
combination with Projected
Area Tolerance to give an
overall feature volumetric
tolerance like Parting Line,
Moving Die Component
(MDC) and Angularity
Tolerances.
Projected Area is the area of
a specific feature projected
into a plane. For parting
line and parting line shift
the Projected Area is the
open area of the die cavity
in the parting line plane. For
example, if a die half was
laid down and filled with
liquid, the surface of the
liquid at the parting line is
the Projected Area. For the
MDC, the Projected Area is
determined using the same
method as for a parting line.
See the applicable figures in
the appropriate sections for
Projected Area.
Linear Tolerance is
calculated from a line
perpendicular to any feature.
The Parting Line line is the
total depth of molten material
on both die halves, which is
perpendicular to the parting
line plane. The MDC line is
the length of the core slide
which is perpendicular to the
head of the core slide. Length
of a core slide is determined
from the point where the core
first engages the die to its full
insertion point.
Projected Area Tolerance
plus Linear Tolerance equals
feature tolerance (tolerance
of the volume of the part).
See Volumetric Tolerance
diagram on the facing page.

1) W
hat is the difference between Standard and Precision Tolerances?
See pages 4A-3 and 4A-4, Standard and Precision Tolerances.
2) W hat is a Parting Line Shift?
See pages 4A-19 and 4A-20, Parting Line Shift.
3) If my casting requires machining, how should the casting be dimensioned?
See page 4A-40 and 4A-41, Machining Stock Allowances.
4) How large should a cast-in hole be if threads need to be tapped or formed in the casting?
See page 4A-34 and 4A-35, Cored Holes for Cut Threads. Also see pages 4A-36 and 4A-37,
Cored Holes for Formed Threads.
5) W
hat type of draft should be used on exterior and interior walls?
See pages 4A-21 through 4A-24, Draft Requirements.
6) W hat type of flatness tolerance can be expected on a cast surface?
See pages 4A-29 and 4A-30, Flatness Requirements.
1 Introduction
Die casting requires a specific degree of precision for the end product to meet the requirements
of form, fit and function. However there is a cost associated with increased precision.
Some of the costs associated with a higher degree of tolerance include:
Decreased die life due to wear that puts die dimensions outside of specified high precision tolerance
More frequent die repair or replacement to maintain a high precision tolerance
More frequent shutdown (shorter production runs) to repair or replace dies
More frequent part or die inspections to ensure high precision tolerance is maintained
Potential for higher scrap rate for not maintaining specified high precision tolerance
A good casting design will take into account not only the precision required to meet the requirements of form, fit and function, but will also take into account maximizing tolerance to achieve a
longer die life and longer production runs with less inspections. This will result in less potential for
scrap and more acceptable parts because the tolerance range for acceptable parts has increased.
In section 4A tolerance will be specified in two values. Standard Tolerance is the lesser degree of
precision that will meet most applications of form, fit and function. It is specified in thousandths of an
inch (0.001) or hundredths of a millimeter (0.01). Degree of variation from design specified values is
larger than that of Precision Tolerance as shown in graphical representation at the end of section 4A.
Precision Tolerance is a higher degree of precision used for special applications where form,
fit and function are adversely affected by minor variations from design specifications. Precision
Tolerance is also specified in thousandths of an inch or hundredths of a millimeter. However, its
variation from design specified values is less than that of Standard Tolerances.
Examples of tolerance application may be an engine casting that uses Standard Tolerance.
Form, fit and function are not critical since moving parts will be encased in sleeves that are cast
into place. Variations in size will be filled with cast metal.
Standard Tolerance meets the criteria for this application as part of the design. However a gas line fitting may require a higher degree of precision so that mating parts fit together to prevent leaks. Precision
gas fittings may cost more to produce because of the higher degree of precision that must be maintained.
Degree of precision depends on the applications of form, fit and function which resides with
the design engineers expectation of part performance.
Cast components can be specified and produced to an excellent surface finish, close dimensional tolerances and to minimum draft, among other characteristics.
All of the capabilities of the casting process, specified to maximum degree, will rarely, if ever, be
required in one cast part. For the most economical production, the design engineer or specifier should
attempt to avoid such requirements in a single component.
It is important for the product designer and engineer to understand precisely how todays die
casting process can be specified in accordance with the capabilities of the die casting industry.
4A-2

2
Section Objectives
The Engineering and Design Sections of this document are prepared to aid product specifiers in
achieving the most cost-effective results through net-shape and near-net-shape casting production. They present both English and Metric values on the same page.
Section 4A presents standard/precision tolerances and other specifications for die cast parts ranging from a fraction of an inch (several millimeters) to several feet (meter) in size. Material weight
ranges from a fraction of an ounce (several milligrams) to thirty pounds (kilograms) or more.
Section 4B presents standard/precision tolerances and other specifications for miniature die cast parts
ranging from hundredths of an inch (tenths of a millimeter) to several inches (several centimeters) in size.
Material weights ranging from a fraction of an ounce (several milligrams) to about 16 ounces (454 grams).
Section 5 presents Geometric Dimensioning, which provides guidelines for applying tolerances
to cast part specifications.
These sections provide information for developing the most economically produced design that
meets the specifications of form, fit and function.
Standard and Precision Tolerances
As noted in the contents for this section, seven important sets of tolerancing guidelines are
presented here as both Standard and Precision Tolerances:
Linear dimensions
Volumetric
Tolerance
for Across
Parting
Line Features
(See diagram on this page.)
Parting Line Projected Area
is defined by the horizontal
center line shown in the figure
below. Its dimensions are 1.00
inch wide by (7.50 - 1.50)
inches long. The Projected
area is (1.00 x 6.00) or 6.00
in. sq. This is the surface
area used for features across
the parting line. Tolerance is
expressed in inches.
Linear Dimension (depth of
cavity on both die halves) is
1.40 inches. This is the linear
dimension used to determine
Linear Tolerance.
Feature Tolerance is Projected Area Tolerance plus
Linear Area Tolerance.
Dimensions across parting Lines
Dimensions formed by moving die components (MDC)

Angularity
Draft
Flatness
Cored holes for threads

The following features are only specified in Standard Tolerance. Unlike the features above, parts
that exceed the following tolerances will not meet the requirements of form, fit and function. These
features are specified at the maximum tolerance to meet their requirements. These features include:
Concentricity
Parting Line Shift
Graphical
Representation
Throughout section 4A there
is graphical representation of
specific feature tolerances.
Precision tolerances are
generally closer to design
specifications than standard
tolerances. The x-axis along
y-axis at zero indicates actual
design specification. Graph
lines indicate the maximum
allowable deviation from
design specification.
Volume = 6.64 in3
4A-3
4A

Standard Tolerances
Standard Tolerances cover expected values consistent with high casting cycle speeds, uninterrupted production, reasonable die life and die maintenance costs, as well as normal inspection,
packing and shipping costs.
Such tolerances can normally be achieved by the widely available production capabilities of
casters practicing standard methods and procedures. Conformity to these standards by designers
assures the most predictable service and lowest cost.
Precision Tolerances
Critical requirements for dimensional accuracy, draft, etc.., beyond the Standard Tolerances
presented, can be specified when required.
Precision Tolerances are presented on the page following the Standard Tolerances for the same
characteristic. The values shown for Precision Tolerances represent greater casting accuracy. See
graphical comparison of Standard and Precision Tolerances throughout section 4A. Part precision tolerances involve extra precision in die construction and/or special process controls during
production. The use of new technologies and equipment aid in maintaining Precision Tolerance.
While early consultation with the caster can sometimes result in selected special precision requirements being incorporated with little additional cost, such tolerances should be specified only where
necessary.
It should be noted that the tolerances shown must, of necessity, be guidelines onlyhighly
dependent on the particular shape, specific features and wall thickness transitions of a given part
design. These factors, under the control of the product designer, greatly influence the ability of
the casting process to achieve predetermined specifications in the final cast part.
Where a number of critical requirements are combined in a single casting, early caster evaluation of a proposed design is essential. Design modifications for more cost-efficient casting can
nearly always be made. Without such feedback, additional costs can usually be expected and the
design, as originally planned, may not be producible by die casting.
When specific designs are examined, tolerances even closer than the Precision Tolerances
shown can often be held by repeated production sampling and recutting of the die casting die,
together with production capability studies. While such steps will result in additional tooling
and production costs, the significant savings that can result by eliminating substantial secondary
machining and/or finishing operations can prove highly cost effective.
When attempting to hold tolerances closer than Precision Tolerances steel safe practrices
should be utilized when building dies and tooling.
Production Part Technologies
This section presents advantages and limitations of various production technologies for a simple
part such as the one shown in Fig. 4A-1. The section that follows presents the die cast alternative
and its advantages and limitations.
Metal Stamping Alternative

This part design, as pictured in Fig. 4A-1 and if designed to a minimum thickness without
additional complexities, could be considered for volume production by the metal stamping process.
Fig. 4A-1 Proposed component.
4A-4

Metal stamping lends itself to high-speed production with infrequent die replacement or repair.
However, the stamping process can only produce features that are apparent on both sides of a thin
part. Indentations on one side of the part appear as ridges on the other side of the part. Critical
bends in the metal surface of stamped products become areas of weakness where metal is
formed to make the bend. Complex features within the layer of metal are impossible without
additional stamped parts and assembly. Thicker parts require higher stamping pressure which
compounds metal fatigue at critical bends. This is similar to a large tree snapping in the wind
where a sapling will bend. Multiple stamped layers and assembly would exceed the cost of the
die cast alternative.
Extrusion Alternative
If the part design required stock depth beyond stamping capabilities, the extrusion process
might be a production alternative for creating such a profileunless complex additional interior
features were desirable, such as those shown in Fig. 4A-1.
When total costs of a product assembly can be significantly reduced by a more robust part design,
as that suggested by Fig. 4A-1, the production process which allows such design freedom is the
better choice. The extrusion process produces a uniform internal structure in one axis such as a bar
or a tube. End features or variations within the axis are impossible. A part, such as the one shown
in Fig. 4A-1, has design feature variations on all axes therefore extrusion of this part is not possible
without multiple operations which would exceed the cost of the die cast alternative.
4A
Machining Alternative
Automated machining could produce product features as shown in Fig. 4A-1. Complex features
would require additional operations for each piece. This would be very time consuming and
would place tremendous wear on production equipment especially during large volume production. As volumes increased, machining would become a very high-cost production option.
Foundry Casting Alternative

Foundry casting plus secondary machining might be an alternative for this part. Foundry casting
involves pouring molten metal into a mold. Without the pressure of die, SSM or squeeze casting
to force metal into critical paths, around tight turns, and into small features of the mold. Foundry
casting can not achieve the detail and precision of die, SSM or squeeze casting. The Foundry
casting process is relatively slow in that gravity fills and mold positions take time to achieve.
Extensive secondary machining is required for Foundry castings when close tolerances are
required. This is not only costly but time consuming. Foundry casting is usually reserved for large
iron castings with very little intricate detail. It is not considered as a high volume process. Netshape die casting can become the more cost-effective solution, often at low production volumes.
F ig . 4A-1A P roposed component with added features and design modified for cost -effective die cast ing production , showing orientation in the die casting die and core slide (moving die component) to
cast the additional features .
4A-5

Investment Casting Alternative
At low volumes the investment casting process could be considered to achieve precision tolerances. At higher volumes die casting would be the clear choice.
Powdered Metal Alternative

The powdered metal process offers dimensional accuracy for many parts. It cannot achieve the
more complex configurations, detailed features or thinner walls which die casting can easily
produce to net or near-net shape.
Plastic Molded Alternative

Plastic injection molding could achieve the designed configuration shown in Fig. 4A-1, but if
requirements of rigidity, creep resistance, and strengthparticularly at elevated temperatures
were important, plastics would be questionable. The longevity of plastic components is normally
substantially less than that of metal components. Plastics products are subject to failure modes such
as sunlight, radiation, heat and various chemicals. The designer needs to ensure that the application
and duration of the end product will meet the customers needs and expectations. Additionally, the
preference for use of a recycled raw material as well as the potential for eventual recycling of the
product at the end of its useful life would also support a decision for die casting.
Die Casting, SSM and Squeeze Cast Part Design
Fig. 4A-1A, illustrates a good design practice for die, SSM and squeeze casting production.
Sharp corners have been eliminated and the design has been provided with the proper draft and
radii to maximize the potential die life and to aid in filling the die cavity completely under high
production cycle speeds.
Typical wall thicknesses for a cast design range from 0.040 in. (1.016 mm) to 0.200 in. (5.08 mm),
depending on alloy, part configuration, part size and application.
Smaller castings with wall sections as thin as 0.020 in. (0.50 mm) can be cast, with die caster
consultation. For extremely small zinc parts, miniature die casting technology can be used to cast still
thinner walls. See section 4B for information on miniature die casting.
Fig. 4A-1 will be used elsewhere in this section to present dimensional tolerances, specifically
as they relate to part dimensions on the same side of the die half, across the parting line, and
those formed by moving die components.
Note: Because dies wear over the course of producing castings, it should be noted that the number of shots on a die
prior to repair or replacement will be less for tighter casting tolerances and greater for wider casting tolerances.
Fig. 4A-1 will also be used in the Geometric Dimensioning Section to show how datum structure can influence
tooling and tolerances.
4A-6
NADCA
S-4A-1-15
STANDARD
TOLERANCES
Linear Dimensions: Standard Tolerances
The Standard Tolerance on any of the features labeled in the adjacent drawing, dimension E1
will be the value shown in table S-4A-1 for dimensions of features formed in the same die part.
Tolerance must be increased for dimensions of features formed by the parting line or by moving
die parts to allow for movement such as parting line shift or the moving components in the
die itself. See tables S-4A-2 and S-4A-3 for calculating tolerance of moving die components or
parting line shift. Linear tolerance is only for fixed components to allow for growth, shrinkage
or minor imperfections in the part.
Tolerance is the amount of variation from the parts nominal or design feature.
For example, a 5 inch design specification with 0.010 tolerance does not require the amount
of precision as the same part with a tolerance of 0.005. The smaller the tolerance number, the
more precise the part must be (the higher the precision). Normally, the higher the precision
the more it costs to manufacture the
part because die wear will affect more
E1
precise parts sooner. Production runs
will be shorter to allow for increased die
maintenance. Therefore the objective is to
E1
have as much tolerance as possible without
affecting form, fit and function of the part.
PL
Example:
Aluminum Casting
E1 = 5.00 in (127 mm)
Standard Tolerance (from Table S-4A-1)
First inch (25.4 mm)
.010 in (0.25 mm)
Each additional inch (25.4 mm)
4x
.001 in (0.025 mm)
.014 in (0.35 mm)
Linear dimension tolerance only applies to linear dimensions formed in the same die half
with no moving components.
The values shown represent

Standard Tolerances, or normal
casting production practice
at the most economical level.
For greater casting accuracy
see Precision Tolerances for
this characteristic on the facing
page. Be sure to also address
the procedures referred to in
Section 7, Quality Assurance,
sub-section 3, 4 and 5.
Significant numbers indicate
the degree of accuracy in calculating precision. The more
significant numbers in a specified tolerance, the greater the
accuracy. Significant number
is the first non-zero number to
the right of the decimal and
all numbers to the right of
that number. For example,
0.014. The degree of
accuracy is specified by the
three significant numbers
140. This is not to be
confused with tolerance
precision. A tolerance limit of
0.007 has a higher degree of
precision because it is closer to
zero tolerance. Zero tolerance
indicates that the part meets
design specifications exactly.
Linear Standard and Linear
Precision tolerances are
expressed in thousandths of an
inch (.001) or hundredths of a
millimeter (.01).
Notes:
Casting configuration and
shrink factor may limit some
dimension control for achieving a specified precision.
Linear tolerances apply to
radii and diameters as well as
wall thicknesses.
Table S-4A-1 Tolerances for Linear Dimensions (Standard)

In inches, two-place decimals (.xx); In millimeters, single-place decimals (.x)
Casting Alloys
Length of Dimension "E1"
Zinc
Aluminum
Magnesium
Copper
Basic Tolerance
up to 1" (25.4mm)
0.010
(0.25 mm)
0.010
(0.25 mm)
0.010
(0.25 mm)
0.014
(0.36 mm)
Additional Tolerance
for each additional inch over 1" (25.4mm)
0.001
(0.025 mm)
0.001
(0.025 mm)
0.001
(0.025 mm)
0.003
(0.076 mm)
It is important to note that

this section covers tolerances
that are achievable for both
Standard and Precision Die
Castings. However, in todays
Six Sigma World, Capability
may still be a question. Die
Cast Tools are often built to
allow for maximum tool life
and process variations that
can detract from the process
and actual tool capabilities.
Six Sigma variation and CPK
should be discussed with
the Die Caster in advance of
tool construction. Frequently
repeatability (CP rather than
CPK) is the goal in the as cast
state. To build a tool at nominal dimensions to get a good
CPK will lead to shorter tool
life and added rejects to the die
caster for process variations.
4A-7
4A
NADCA
P-4A-1-15
PRECISION
TOLERANCES
Linear tolerances apply to

radii and diameters as well
as wall thicknesses.
Methods for
Improving
Precision:
1. By repeated sampling
and recutting of the die
cast tool, along with
capability studies, even
closer dimensions can be
held. However, additional
sampling and other costs
may be incurred.
2. For zinc die castings,
tighter tolerances can be
held, depending on part
configuration and the use
of artificial aging. Artificial aging (also known
as heat treating) may be
essential for maintaining
critical dimensions in zinc,
particularly if the part is
to be machined, due to the
creep (growth) characteristics of zinc. The die caster
should be consulted during
the part design stage.
3. In the case of extremely
small zinc parts, weighing
fractions of an ounce, special die casting machines
can achieve significantly
tighter tolerances, with
zero draft and flash-free
operation. See Section 4B,
Miniature Die Casting.
Note:
Standard and Precision Die
Castings. However, in todays
Six Sigma World, Capability
Cast Tools are often built to
and actual tool capabilities.
Six Sigma variation and CPK
should be discussed with
the Die Caster in advance of
tool construction. Frequently
repeatability (CP rather than
CPK) is the goal in the as cast
state. To build a tool at nominal dimensions to get a good
CPK will lead to shorter tool
life and added rejects to the die
caster for process variations.
4A-8
Linear Dimensions: Precision Tolerances

Precision Tolerance on any of the features labeled in the adjacent drawing, dimension E1 will
be the value shown in table P-4A-1 for dimensions between features formed in the same die
part. Tolerance must be increased for dimensions of features formed by the parting line or by
moving die parts to allow for movement
such as parting line shift or the moving
E1
components in the die itself. See tables
P-4A-2 and P-4A-3 for calculating precision of moving die components or parting
E1
line shift. Linear tolerance is only for fixed
components to allow for growth, shrinkage
PL
or minor imperfections in the part.
Example:
Aluminum Casting
E1 = 5.00 in (127 mm)
Precision Tolerance (from Table P-4A-1)
First inch (25.4 mm)
.002 in (0.05 mm)
Each additional inch (25.4 mm)
4x
.001 in (0.025 mm)
.006 in (0.15 mm)
Linear dimension tolerance only applies to linear dimensions formed in the same die half with no
moving components.
Table P-4A-1 Tolerances for Linear Dimensions (Precision)
In inches, three-place decimals (.xxx); In millimeters, two-place decimals (.xx)
Casting Alloys
Length of Dimension "E1"
Zinc
Aluminum
Magnesium
Copper
Basic Tolerance
up to 1" (25.4mm)
0.002
(0.05 mm)
0.002
(0.05 mm)
0.002
(0.05 mm)
0.007
(0.18 mm)
for each additional inch over 1" (25.4mm)
0.001
(0.025 mm)
0.001
(0.025 mm)
0.001
(0.025 mm)
0.002
(0.05 mm)
Linear Tolerance
0.05
0.045
0.04
Tolerance in +/- Inches
The Precision Tolerance values

shown represent greater casting
accuracy involving extra precision in die construction and/or
special control in production.
They should be specified only
when and where necessary,
since additional costs may
be involved. Be sure to also
address the procedures referred
to in Section 7, Quality Assurance, sub-section 3, 4 and 5.
0.035
Al, Mg, Zn Stand. Tol.

Cu Stand. Tol.
Al, Mg, Zn Precis. Tol.
Cu Precis. Tol.
0.03
0.025
0.02
0.015
0.01
0.005
0
1
2
3
4
5
6
7
8
9
10
11
12
(25.4) (50.8) (76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Linear Dimension in Inches (mm)
NADCA
S-4A-2-15
STANDARD
TOLERANCES
Parting Line: Standard Tolerances
Parting Line Tolerance is the additional tolerance needed for cross parting line dimensions in
order to account for die separation (die blow).. This is not to be confused with Parting Line
Shift Tolerance (cavity mismatch) which is the maximum amount die halves shift from side
to side in relation to one another.
Parting Line Tolerance is a function of the
Projected Area of the part. The Projected
Area is a two dimensional area measurement
calculated by projecting the three dimensional
part onto a plane, which in this case is the
cavity surface at the parting line. An easy
way to visualize the Projected Area is by
what shadow a casting would project onto the
cavity surface.
The Parting Line Tolerance is always a plus
tolerance since a completely closed die has
0 separation. Excess material and pressure
will force the die to open along the parting line plane creating an oversize condition. The
excess pressure will cause the part to be thicker than the ideal specification. It is important
to understand that Table S-4A-2 (Parting Line Tolerance) does not provide the Total Cross
Parting Line Tolerance by itself. The Total Cross Parting Line Tolerance for any dimension
is the sum of the Linear Tolerance (derived from the part thickness) in addition to the
Parting Line Tolerance.
Thus, information from the Parting Line Tolerance table S-4A-2 in combination with the
formerly discussed Linear Tolerance table S-4A-1 give a true representation of Total Cross
Parting Line Tolerance. Note that the tolerances in the table apply to a single casting regardless of the number of cavities.
Example: An aluminum die casting has 75 in 2 (483.9 cm 2) of Projected Area on the parting die plane. From table S-4A-2, the Parting Line Tolerance is +0.012. This is combined
with the total part thickness tolerance from table S-4A-1 to obtain the Total Cross Parting
Line Tolerance.
The total part thickness including both die halves is 5.00 in. (127 mm) which is measured
perpendicular to the parting die plane (dimension E 2 E1). From table S-4A-1, the Linear
Tolerance is 0.010 for the first inch and 0.001 for each of the four additional inches. The
Linear Tolerance of 0.014 inches is combined with the Parting Line Tolerance of +0.012 to
yield a Standard Cross Parting Line Tolerance of +0.026/-0.014 in. or in metric terms 0.35
mm from Linear Tolerance table S-4A-1 plus +0.30 mm from Parting Line Tolerance table
S-4A-2 = +0.65/-0.35 mm.

Standard Tolerances, or
normal die casting production practice at the most
economical level. For
greater casting accuracy
see Precision Tolerances
for this characteristic on
the facing page. Be sure to
also address the procedures
referred to in Section 7,
Quality Assurance, subsection 3, 4 and 5.
Die Shift:
Parting line die shift,
unlike parting line
separation and moving die
component tolerances, is a
left/right relationship with
possible consequences.
It can shift in four directions, based on a combination of part features, die
construction and operation
factors. It can occur at
any time and its tolerance
consequences should be
discussed with the die
caster at the design stage
to minimize any impact on
the final die casting.
Notes:
All values for part dimensions which run across the
die parting line are stated
as a plus tolerance only.
The die casting die at a die
closed position creates the
bottom of the tolerance
range, i.e., 0.000 (zero).
Due to the nature of the die
casting process, dies can
separate imperceptibly at
the parting line and create
only a larger, or plus side,
tolerance.
Table S-4A-2 Parting Line Tolerances (Standard) Added to Linear Tolerances

Casting Alloys (Tolerances shown are "plus" values only)
Projected Area of Die Casting

inches2 (cm2)
Zinc
Aluminum
Magnesium
Copper
up to 10 in2
(64.5 cm2)
+0.0045
(+0.114 mm)
+0.0055
(+0.14 mm)
+0.0055
(+0.14 mm)
+0.008
(+0.20 mm)
11 in2 to 20 in2
(71.0 cm2 to 129.0 cm2)
+0.005
(+0.13 mm)
+0.0065
(+0.165 mm)
+0.0065
(+0.165 mm)
+0.009
(+0.23 mm)
21 in2 to 50 in2
(135.5 cm2 to 322.6 cm2)
+0.006
(+0.15 mm)
+0.0075
(+0.19 mm)
+0.0075
(+0.19 mm)
+0.010
(+0.25 mm)
51 in2 to 100 in2

(329.0 cm2 to 645.2 cm2)
+0.009
(+0.23 mm)
+0.012
(+0.30 mm)
+0.012
(+0.30 mm)
101 in2 to 200 in2

(651.6 cm2 to 1290.3 cm2)
+0.012
(+0.30 mm)
+0.018
(+0.46 mm)
+0.018
(+0.46 mm)
201 in2 to 300 in2

(1296.8 cm2 to 1935.5 cm2)
+0.018
(+0.46 mm)
+0.024
(+0.61 mm)
+0.024
(+0.61 mm)
For projected area of die casting over 300 in2 (1935.5 cm2), consult with your die caster.
4A-9
4A
NADCA
P-4A-2-15
PRECISION
TOLERANCES
The Precision Tolerance
values shown represent
involving extra precision
in die construction and/or
They should be specified
only when and where necessary, since additional costs
may be involved. Be sure to
Methods for
Improving
Precision:
and recutting of the die
cast tool, along with
closer dimensions can be
held. However, additional
sampling and other costs
may be incurred.
2. For zinc die castings,
tighter tolerances can be
held, depending on part
configuration and the
use of artificial aging.
Artificial aging (also
known as heat treating)
may be essential for
maintaining critical
dimensions in zinc,
particularly if the part
is to be machined, due
to the creep (growth)
characteristics of zinc.
The die caster should be
consulted during the part
design stage.
Precision Tolerances on dimensions such as E2 E1, which are perpendicular to (across) the die
parting line, will be the linear dimension tolerance from table P-4A-1 plus the value shown in
table P-4A-2. The value chosen from the table below depends on the projected area of the part,
in inches squared or millimeters squared, in the plane of the die parting. Note that the tolerances
shown below are plus side only and based on a single cavity die casting die.
Example: An aluminum die casting has 75 in2
(483.9 cm2) of Projected Area on the parting
die plane. From table P-4A-2, Parting Line
Tolerance is +0.008. This is combined with
PL
the total part thickness tolerance from table
P-4A-1 to obtain the Total Cross Parting Line
E2E1
Tolerance.
Total part thickness including both die halves
is 5.000 in. (127 mm) which is measured perpendicular to the parting die plane (dimension E2 E1).
From table P-4A-1, the Linear Tolerance is 0.002 for the first inch and 0.001 for each of the four
additional inches. The Linear Tolerance of 0.006 is combined with the Parting Line Tolerance of
+0.008 to yield a Precision Cross Parting Line Tolerance of +0.014/-0.006 in. or in metric terms (0.15
mm plus +0.20 mm) = +0.35/-0.15 mm on dimensions that are formed across the parting line.
Table P-4A-2 Parting Line Tolerances (Precision) Added to Linear Tolerances

inches2 (cm2)
Die Casting Alloys (Tolerances shown are "plus" values only)

Zinc
Aluminum
Magnesium
Copper
up to 10 in2
(64.5 cm2)
+0.003
(+0.076 mm)
+0.0035
(+0.089 mm)
+0.0035
(+0.089 mm)
+0.008
(+0.20 mm)
11 in2 to 20 in2
(71.0 cm2 to 129.0 cm2)
+0.0035
(+0.089 mm)
+0.004
(+0.102 mm)
+0.004
(+0.102 mm)
+0.009
(+0.23 mm)
21 in2 to 50 in2
(135.5 cm2 to 322.6 cm2)
+0.004
(+0.102 mm)
+0.005
(+0.153 mm)
+0.005
(+0.153 mm)
+0.010
(+0.25 mm)
51 in2 to 100 in2

(329.0 cm2 to 645.2 cm2)
+0.006
(+0.153 mm)
+0.008
(+0.203 mm)
+0.008
(+0.203 mm)
101 in2 to 200 in2

(651.6 cm2 to 1290.3 cm2)
+0.008
(+0.203 mm)
+0.012
(+0.305 mm)
+0.012
(+0.305 mm)
201 in2 to 300 in2

(1296.8 cm2 to 1935.5 cm2)
+0.012
(+0.305 mm)
+0.016
(+0.406 mm)
+0.016
(+0.406 mm)
0.03
0.025
Tolerance in + Inches
3. In the case of extremely

small zinc parts, weighing
fractions of an ounce, special die casting machines
can achieve significantly
operation. See Section 4B,
Parting Line: Precision Tolerances
Al, Mg Stand. Tol.

Cu Stand. Tol.
Zn Stand. Tol.
0.02
Al, Mg Precis. Tol.

Cu Precis. Tol.
0.015
Zn Precis. Tol.
0.01
0.005
0
10 (64.50)
4A-10
20 (129.0)
50 (322.6)
100 (645.2)
200 (1290)
Projected Area in Inches Square (cm sq)
300 (1935)
NADCA
S-4A-3-15
STANDARD
TOLERANCES
Moving Die Components (MDC): Standard Tolerances
Moving Die Components Tolerance can affect final part performance similar to Parting Line
Tolerance. When the core is fully inserted into the die, the minimum tolerance is zero. As excess
material and pressure are exerted in the die, the core can slide out creating an oversized condition.
A MDC Tolerance has been developed to ensure minimal impact on form, fit and function by
specifying limits to the oversize condition.
Similar to Parting Line Tolerance,
MDC Standard Tolerance is a function
of the Moving Die Component (MDC)
Tolerance plus Linear Tolerance. Linear
Tolerance is calculated based on the
length of movement of the core slide
Core
PL
Slide
along dimension E3 E1. Table S-4A-1
is used to determine Linear Tolerance.
The linear dimension is not the entire
length of E3 E1 but is only the length
E3E1
of the core slide from where the core
slide first engages the die to its full
insertion position. Linear dimension is
normally perpendicular to the Projected
Area.
Projected Area is the area of the core head that faces the molten material. MDC Tolerance for
moving die components is determined from table S-4A-3. The open area (cavity) on the end view of
the part in figure 4A-1A at the beginning of this section shows the projected area. Projected Area
Tolerance plus Linear Tolerance provide MDC Standard Tolerance for the volume of the part. Note
that the tolerances in the table apply to a single casting regardless of the number of cavities.
Example: An aluminum casting has 75 in 2 (483.9 cm 2) of Projected Area calculated from the
core slide head facing the molten material. From table S-4A-3, MDC Tolerance is +0.024. This
is combined with the length of the core slide Linear Tolerance from table S-4A-1 to obtain the
MDC Standard Tolerance. The total core slide length of 5.00 in. (127 mm) is measured from
where the core engages the part to full insertion in the plane of dimension E3 E1 to determine
Linear Tolerance length. From table S-4A-1, the Linear Tolerance is 0.010 for the first inch
and 0.001 for each of the four additional inches.
The Linear Tolerance of 0.014 inches is combined with the MDC Tolerance of +0.024 to
yield a MDC Standard Tolerance of +0.038/-0.014 in.
MDC Metric Standard Tolerance is +0.96/-0.35 mm = (0.35 mm) + (+0.61 mm) on dimensions formed by moving die components.

normal die casting production practice at the most
economical level. For
see Precision Tolerances
for this characteristic on
the facing page. Be sure to
Die Shift:
Parting line die shift,
unlike parting line
separation and moving die
component tolerances, is a
left/right relationship with
possible consequences.
It can shift in four directions, based on a combination of part features, die
construction and operation
factors. It can occur at
any time and its tolerance
consequences should be
discussed with the die
caster at the design stage
to minimize any impact on
the final die casting.
Notes:
All values for part dimensions which run across the
die parting line are stated
as a plus tolerance only.
The die casting die at a die
closed position creates the
bottom of the tolerance
range, i.e., 0.000 (zero).
Due to the nature of the
die casting process, dies
can separate imperceptibly
at the parting line and
create only a larger, or
plus side, tolerance.
Table S-4A-3 MDC Tolerances (Standard) Added to Linear Tolerances

inches2 (cm2)

Zinc
Aluminum
Magnesium
Copper
up to 10 in2
(64.5 cm2)
+0.006
(+0.15 mm)
+0.008
(+0.20 mm)
+0.008
(+0.20 mm)
+0.012
(+0.305 mm)
11 in2 to 20 in2
(71.0 cm2 to 129.0 cm2)
+0.009
(+0.23 mm)
+0.013
(+0.33 mm)
+0.013
(+0.33 mm)
21 in2 to 50 in2
(135.5 cm2 to 322.6 cm2)
+0.013
(+0.33 mm)
+0.019
(+0.48 mm)
+0.019
(+0.48 mm)
51 in2 to 100 in2

(329.0 cm2 to 645.2 cm2)
+0.019
(+0.48 mm)
+0.024
(+0.61 mm)
+0.024
(+0.61 mm)
101 in2 to 200 in2

(651.6 cm2 to 1290.3 cm2)
+0.026
(+0.66 mm)
+0.032
(+0.81 mm)
+0.032
(+0.81 mm)
201 in2 to 300 in2

(1296.8 cm2 to 1935.5 cm2)
+0.032
(+0.81 mm)
+0.040
(+1.0 mm)
+0.040
(+1.0 mm)
4A-11
4A
NADCA
P-4A-3-15
PRECISION
TOLERANCES
Precision Tolerance values
shown represent greater casting accuracy involving extra
precision in die construction and/or special control
in production. They should
be specified only when and
where necessary, since additional costs may be involved.
Be sure to also address the
procedures referred to in Section 7, Quality Assurance,
sub-section 3, 4 and 5.
Methods for
Improving
Precision:
and recutting of the
die casting tool,
along with production
closer dimensions can
be heldat additional
sampling or other costs.
2. The die casting process
may cause variations
to occur in parting
line separation. Thus,
tolerances for dimensions that fall across the
parting line on any given
part should be checked
in multiple locations,
i.e., at four corners and
on the center line.
3. In the case of
extremely small zinc
parts, weighing fractions
of an ounce, special die
casting machines can
achieve significantly
operation. See section 4B
Moving Die Components (MDC): Precision Tolerances

Precision Tolerances attainable on die cast dimensions such as E3 E1 formed by a moving die
component will be the linear tolerance from table P-4A-1 plus the value shown in table P-4A-3.
Linear Tolerance is the length of the core slide. Projected Area is the area of the head of the core
slide facing the molten material. The value chosen from table P-4A-3 depends on the Projected
Area of the portion of the die casting formed by the moving die component (MDC) perpendicular to the direction of movement. Note that tolerances shown are plus side only.
Example: An aluminum die casting has 75 in 2
(483.9 cm 2) of Projected Area calculated from
the core slide head facing the molten material.
PL
From table P-4A-3, MDC Tolerance is +0.018.
This is combined with the length of the core
slide Linear Tolerance from table P-4A-1 to
E3E1
obtain the MDC Precision Tolerance.
The total core slide length of 5.00 in. (127 mm)
is measured from where the core engages the part to full insertion in the plane of dimension E3 E1 to
determine Linear Tolerance length from table P-4A-1, the Linear Tolerance is 0.002 for the first inch
and 0.001 for each of the four additional inches. The Linear Tolerance of 0.006 inches is combined
with the MDC Tolerance of +0.018 to yield a MDC Precision Tolerance of +0.024/-0.006 in.
MDC Metric Precision Tolerance is +0.607/-0.15 mm = (0.15 mm) +(+0.457 mm) on dimensions formed by MDC.
Core
Slide
Table P-4A-3 MDC Tolerances (Precision) Added to Linear Tolerances

inches2 (cm2)

Zinc
Aluminum
Magnesium
Copper
up to 10 in2
(64.5 cm2)
+0.005
(+0.127 mm)
+0.006
(+0.152 mm)
+0.005
(+0.127 mm)
+0.010
(+0.254 mm)
11 in2 to 20 in2
(71.0 cm2 to 129.0 cm2)
+0.007
(+0.178 mm)
+0.010
(+0.254 mm)
+0.007
(+0.178 mm)
21 in2 to 50 in2
(135.5 cm2 to 322.6 cm2)
+0.010
(+0.254 mm)
+0.014
(+0.356 mm)
+0.010
(+0.254 mm)
51 in2 to 100 in2

(329.0 cm2 to 645.2 cm2)
+0.014
(+0.356 mm)
+0.018
(+0.457 mm)
+0.014
(+0.356 mm)
101 in2 to 200 in2

(651.6 cm2 to 1290.3 cm2)
+0.019
(+0.483 mm)
+0.024
(+0.61 mm)
+0.019
(+0.483 mm)
201 in2 to 300 in2

(1296.8 cm2 to 1935.5 cm2)
+0.024
(+0.61 mm)
+0.030
(+0.762 mm)
+0.024
(+0.61 mm)
0.045
0.04
0.035
0.03
0.025
0.02
Moving Die Tolerance

Al, Mg Stand. Tol.
Cu Stand. Tol.
Zn Stand. Tol.
Al Precis. Tol.
Cu Precis. Tol.
Mg, Zn Precis. Tol.
0.015
0.01
0.005
0
10
(64.5)
20
(129.0)
50
(322.6)
100
(645.2)
200
(1290.)
300
(1935.)
4A-12
NADCA
S/P-4A-4-15
STANDARD /PRECISION
TOLERANCES
Angularity Tolerances (Plane surfaces): Standard & Precision Tolerances
Angularity refers to the angular departure from the designed relationship between elements of
the die casting. Angularity includes, but is not limited to, flatness, parallelism and perpendicularity. The angular accuracy of a die casting is affected by numerous factors including size of the
die casting, the strength and rigidity of the die casting and die parts under conditions of high
heat and pressure, position of moving die components, and distortion during handling of the die
casting. Angularity is not a stand alone tolerance. Angularity Tolerance is added to other part
feature tolerances. For example, if determining tolerance for angular features at the Parting Line,
Parting Line Tolerance and Angularity Tolerance would be added to yield total part tolerance.
Angularity is calculated from the following tables based on the surface length that is impacted
by angularity and where the surface is located.
There are four tables for calculating Standard and Precision Angularity Tolerance.
Table S/P-4A-4A provides Angularity Tolerance for features in the same die half.
Table S/P-4A-4B provides Angularity Tolerance for features that cross the parting line.
Table S/P-4A-4C provides Angularity Tolerance for MDC features that are in the same die half.
Table S/P-4A-4D provides Angularity Tolerance for multiple MDC features or MDC features
that cross the parting line. The more MDCs involved, the more tolerance is necessary hence
multiple tables.
Standard Tolerances shown

represent normal die casting
production practice at the
most economical level.
shown represent greater
casting accuracy involving extra precision in die
construction and/or special
control in production. They
should be specified only
be involved.
4A
Applicability of Standard
This standard may be applied to plane surfaces of die castings for all alloys. Its tolerances are to
be considered in addition to those provided by other standards.
Angularity Tolerances - All Alloys

Tolerances required vary with the length of the surface of the die casting and the relative
location of these surfaces in the casting die.
Table S/P-4A-4A Angularity Tolerance Features in Same Die Half
Type
Surfaces 3
(76.2 mm) or
less
.005 (.13 mm)
.003 (.08 mm)
Standard
Precision
Each 1 (25.4
mm) over 3
(76.2 mm)
.001 (.025 mm)
.001 (.025 mm)
SURFACE B
DATUM A
Fixed Angularity Tolerance Same Die Half

0.016
Standard Tol.
Tolerance in Inches
0.014
Precision Tol.
0.012
0.01
0.008
0.006
0.004
0.002
0
3
(76.2)
4
(101.6)
5
(127.0)
6
(152.4)
7
(177.8)
8
(203.2)
9
(228.6)
10
(254.0)
11
(279.4)
12
(304.8)
Linear Surface in Inches (mm)
4A-13
NADCA
S/P-4A-4-15
STANDARD /PRECISION
TOLERANCES
shown represent greater casting accuracy involving extra
precision in die construction and/or special control
in production. They should
where necessary, since additional costs may be involved.
Methods for
Improving
Precision:
and recutting of the
die casting tool,
along with production
closer dimensions can
be heldat additional
sampling or other costs.
2. The die casting process
may cause variations
to occur in parting
line separation. Thus,
tolerances for dimensions that fall across the
parting line on any given
part should be checked
in multiple locations,
i.e., at four corners and
on the center line.
3. In the case of
extremely small zinc
parts, weighing fractions
of an ounce, special die
casting machines can
achieve significantly
operation. See section 4B

Same Die Half
Example: Standard Tolerances Surface -B- and the datum plane -A- are formed by the same die half.
If surface -B- is 5 (127 mm) long it will be parallel to the datum plane -A- within .007 (.18 mm).
[.005 (.13 mm) for the first 3 (76.2 mm) and .002 (.05 mm) for the additional length.]
Example: Precision Tolerances Surface -B- and the datum plane -A- are formed by the same die half.
If surface -B- is 5 (127 mm) long it will be parallel to the datum plane -A- within .005 (.13 mm).
Across Parting Line
Example: For Standard Tolerances Surface -B- and the datum plane -A- are formed in opposite die sections. If surface -B- is 7 (177.8 mm) long it will be parallel to the datum plane -A- within .014 (.36 mm).
Example: For Precision Tolerances Surface -B- and the datum plane -A- are formed in opposite die sections. If surface -B- is 7 (177.8 mm) long it will be parallel to the datum plane -A- within .009 (.23 mm).
[.005(.13 mm) for the first 3 (76.2 mm) and .004 (.10 mm) for the additional length.]
Table S/P-4A-4B Angularity Tolerance Feature that Cross Parting Line
Type
Standard
Surfaces 3
(76.2 mm) or
less
.008 (.20 mm)
Precision
.005 (.13 mm)
Each 1 (25.4
mm) over 3
(76.2 mm)
.0015 (.038
mm)
.001 (.025 mm)
SURFACE B
DATUM A
Fixed Angularity Tolerance Across PL

0.025
Tolerance in Inches
Standard Tol.
0.02
Precision Tol.
0.015
0.01
0.005
0
3
(76.2)
4
5
6
7
8
9
10
11
12
(101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
4A-14
NADCA
S/P-4A-4-15
STANDARD /PRECISION
TOLERANCES

Example: For Standard Tolerances Surface -B- is formed by a moving die member in the same die
section as datum plane -A-. If surface -B- is 5 (127 mm) long it will be perpendicular to the datum
plane -A- within .011 (.28 mm).
Example: For Precision Tolerances Surface -B- and the datum plane -A- are formed in opposite die sections. If surface -B- is 7 (177.8 mm) long it will be parallel to the datum plane -A- within .009 (.23 mm).

be involved.
[.005(.13 mm) for the first 3 (76.2 mm) and .004 (.10 mm) for the additional length.]
4A
Table S/P-4A-4C Angularity Tolerance MDC Features in Same Die Half
Type
Standard
Surfaces 3
(76.2 mm) or
less
.008 (.20 mm)
Precision
.005 (.13 mm)
Each 1 (25.4
mm) over 3
(76.2 mm)
.0015 (.038
mm)
.001 (.025 mm)
SURFACE B
DATUM A
MDC Angularity Tolerance Same Die Half

0.025
Tolerance in Inches
Standard Tol.
Precision Tol.
0.02
0.015
0.01
0.005
0
3
(76.2)
4
5
6
7
8
9
10
11
12
(101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
4A-15
NADCA
S/P-4A-4-15
STANDARD /PRECISION
TOLERANCES
be involved.

Example: For Standard Tolerances Surface -B- is formed by a moving die member and the datum
plane -A- is formed by the opposite die section. If surface -B- is 5 (127 mm) long it will be perpendicular to the datum plane -A- within .017 (.43 mm). [.011 (.28 mm) for the first 3 (76.2 mm) and .006 (.15
mm) for the additional length.]
Surfaces -B- and -C- are formed by two moving die members. If surface -B- is used as the datum plane
and surface -B- is 5 (127 mm) long, surface -C- will be parallel to surface -B- within .017 (.43 mm).
Example: For Precision Tolerances Surface -B- is formed by a moving die member and the datum
plane -A- is formed by the opposite die section. If surface -B- is 5 (127 mm) long it will be perpendicular to the datum plane -A- within .012 (.30 mm). [.008 (.20 mm) for the first 3 (76.2 mm) and .004 (.10
mm) for the additional length.]
Surfaces -B- and -C- are formed by two moving die members. If surface -B- is used as the datum plane
and surface -B- is 5 (127 mm) long, surface -C- will be parallel to surface -B- within .012 (.30 mm).
Table S/P-4A-4C Angularity Tolerance Multiple MDC Features or MDC Features that Cross Parting Line
Type
Surfaces 3
(76.2 mm) or
less
.011 (.28 mm)
.008 (.20 mm)
Standard
Precision
Each 1 (25.4
mm) over 3
(76.2 mm)
.003 (.076 mm)
.002 (.05 mm)
DATUM A
SURFACE B
SURFACE C
MDC Angularity Tolerance Across Parting Line

0.04
Standard Tol.
Tolerance in Inches
0.035
Precision Tol.
0.03
0.025
0.02
0.015
0.01
0.005
0
3
(76.2)
4
5
6
7
8
9
10
11
(101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4)
4A-16
12
(304.8)
NADCA
S-4A-5-15
STANDARD
TOLERANCES
10 Concentricity Tolerances: Varying Degrees of Standard Tolerance

The concentricity of cylindrical surfaces is affected by the design of the die casting. Factors, such
as casting size, wall thickness, shape, and complexity each have an effect on the concentricity of
the measured surface. The tolerances shown below best apply to castings that are designed with
uniformity of shape and wall thickness.
It should be noted that concentricity does not necessarily denote circularity (roundness). Part
features can be considered concentric and still demonstrate an out of roundness condition. See section
5.11, Runout vs. Concentricity, in Geometric Dimensioning & Tolerancing for further explanation.
Concentricity Tolerance is added to other tolerances to determine maximum tolerance for the
feature. For example, a concentric part that may cross the parting line, the tolerance would be
the Concentricity Tolerance added to Parting Line Tolerance to give overall part tolerance. Note
that the tolerances in the table apply to a single casting regardless of the number of cavities.
One Die Section

Concentricity Tolerance in a fixed relationship in one die section is calculated by selecting the
largest feature diameter, (Diameter A ) and calculating the tolerance from Table S-4A-5A using
the chosen diameter. See information in the side column regarding selecting diameters for oval
features. Selected diameter directly impacts degree of precision.
Standard and Precision

Tolerance are not specified
for Concentricity Tolerance
since tolerance is determined from diameter.
As noted in the Concentricity Tolerance description,
concentricity does not
denote roundness. The feature may be oval and still
be concentric. Therefore
tolerance precision may be
variable depending where
diameter is measured.
If minimum diameter is
chosen, the calculated tolerance from the table will
be less indicating a higher
degree of precision.
If maximum diameter is
chosen, then calculated tolerance will be more indicating a more standard
degree of precision.
Diameters chosen between
minimum and maximum
will determine varying
degrees of precision.
Tolerance in Inches
Example: Tolerance in One Die Section An oval feature has a minimum diameter of 7 inches
and a maximum diameter of 8 inches identified by the largest oval in the drawing below. This feature
must fit into a hole with a high degree of precision. The minimum diameter (Diameter A) is chosen
to give the highest degree of precision. From Table S-4A-5A, the basic tolerance for the first 3 inches
is 0.008 inches
(0.20 mm). 0.002
Fixed Concentricity Same Die Half
inches (0.05 mm)
0.03
is added for each
Largest Diameter A
of the additional
0.025
4 inches to yield
0.02
a total Concen0.015
tricity Tolerance
of +0.016 inches
0.01
(+0.40 mm) for
0.005
the 7 diameter.
Concentricity is defined
as a feature having a
common center and is
usually round, circular or
oval. Half the diameter is
the center of the feature.
3
(76.2)
4
5
6
7
8
9
10
11
12
(101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Largest Diameter in Inches (mm)
Table S-4A-5A: Concentricity Tolerance - Same Die Half (Add to other tolerances)
T able S- 4A- 5 Co n cen t ricit y T oler an c es
Surfaces in Fixed Relationship in

One Die Section
PL
A
A
Diameter of Largest
Diameter (A)
Tolerance (T.I.R.)
inches (mm)
Basic Tolerance up to 3
.008 (.20 mm)
(76.2mm)
Additional Tolerance for each
additional inch (25.4 mm) over
3 (76.2mm)
+.002 (.05 mm)
formed
by Opposite Halves of
NADCA Product Specification Standards Surfaces
for Die Castings
/ 2015
Die (single cavity)
4A-17
4A
NADCA
S-4A-5-15
STANDARD
TOLERANCES
Standard and Precision

Tolerance are not specified
for Concentricity Tolerance
since tolerance is determined
from calculated area.
As noted in the Concentricity Tolerance description,
concentricity does not denote
roundness. The feature may
be oval and still be concentric. Concentricity Tolerance
precision is determined from
chosen area and how the area
is calculated.
Concentric Area
Calculation
Round Features are those
with equal diameter
(D) regardless of where
measured. Their area is
calculated by:
(3.14) x [(1/2 D)2]
Oval Feature areas are
determined by averaging
the minimum and maximum
diameters and then using
the same formula as that for
Round Features.
Concentricity Tolerances: Varying Degrees of Standard Tolerance

Opposite Die Halves
When concentric features are in opposite die halves, the area of the cavity at the parting line
determines Concentricity Tolerance. If two concentric features meet at the parting line, it is the
area of the larger feature that determines Concentricity Tolerance from table S-4A-5B. See the
side column for determining the area of a concentric feature. As noted in the side column, degree
of precision is determined from the calculated area when crossing the parting line.
If there is a cavity at the parting line between concentric features that are located in opposite
die halves such as area C on the figure below, area of the cavity determines Concentricity
Tolerance from table S-4A-5B.
Total part tolerance is the combination of Concentricity Tolerance plus other feature
tolerances for the part.
Example: Tolerance in One Die Section An oval feature has a minimum diameter of 6 inches and a
maximum diameter of 8 inches identified as Diameter A. Diameter B is 5 inches. However, the area of
cavity C is 9 by 9 inches. If concentric features meet at the parting line through the squared area C, Concentricity Tolerance is determined from table S-4A-5B by the 9 by 9 area which is 81 inches square. From
table S-4A-5B the Concentricity Tolerance is +.012 inches (+.30 mm).
If concentric features meet at the parting line directly, the area of the larger oval is used to determine
the Concentricity Tolerance from table S-4A-5B. For example, if the minimum diameter is 6 inches
and the maximum diameter is 8 inches, the average diameter is 7 inches. Using the Concentricity Area
Calculation
formula in the
Concentricity Tolerance In Opposite Die Halves
side column,
0.025
the area is
Conc.
T able S- 4A- 5 Co n cen t ricit y T oler
anTol.
c esAcross PL
determined
0.02
to be 38.5
Surfaces in Fixed Relationship in
inches square
0.015
One Die Section
therefore the
Concentricity
0.01
Diameter of Largest
Tolerance (T.I.R.)
Tolerance is
PL
Diameter
(A)
inches (mm)
+.008 inches A
0.005
(+.20 mm).
Tolerance in Inches
Concentricity is defined as
a feature having a common
center and is usually round,
circular or oval. Half the
diameter is the center of the
feature.
Basic Tolerance up to 3
.008 (.20 mm)
(76.2mm)
100 (645)
200 (1290)
300 (1936)
0
50 (323)
Additional Tolerance for each

additional inch (25.4 mm) over +.002 (.05 mm)
Table S-4A-5B: Concentricity Tolerance - Opposite Die Halves3(Add
to other tolerances)
(76.2mm)
Surfaces formed by Opposite Halves of

Die (single cavity)
9 Inches
A
9 Inches
Projected Area (C) of Additional Tolerance

casting
inches (mm)
PL
B
Up to 50 in
2
(323 cm )
2
+ .008 (.20 mm)

2
51 in to 100 in
2
2
(329 cm to 645 cm )
C - Die Cavity
101 in to 200 in
2
2
(652 cm to 1290 cm )
2
+ .016 (.41 mm)
201 in to 300 in
2
2
(1297 cm to 1936 cm )
4A-18
+ .012 (.30 mm)
+ .022 (.56 mm)
NADCA
S-4A-6-15
STANDARD
TOLERANCES
Parting Line Shift: Standard Tolerance

Parting line shift or die shift is a dimensional variation resulting from mismatch between the
two die halves. The shift is a left/right type relationship that can occur in any direction parallel
to the parting line of the two die halves. It has consequences to dimensions unlike parting line
separation and moving die component tolerances. Parting line shift will influence dimensions
that are measured across the parting line including concentricity of features formed by opposite
die halves, and datum structures with datums in opposite die halves. Parting line shift compounds the affects of other tolerances measured across the parting line plane. Parting line shift
can cause a part not to meet the requirements of form, fit and function.
Dies are designed and built with alignment systems to minimize parting line shift. However,
effectiveness of alignment systems in minimizing parting line shift will depend on temperature
variations, die construction, type of die and wear.
Variations in temperature between the two die halves of the die occur during the dies run.
With die steel changing size with temperature variation, the two die halves will change size
with respect to each other. To accommodate these changes in size, the alignment systems
are designed with clearance to eliminate binding during opening and closing of the die. This
clearance is necessary for the operation of the die but will allow a certain amount of parting
line shift. One side of the die may be heated or cooled to compensate for temperature variation
between die halves. One method to compensate for temperature variation is in the design and
gating of the die. Another method is to apply additional die lube between shots to cool the
hotter die half. Minimizing temperature variation between die halves allows for a more precise
alignment system which will limit temperature induced parting line shift.
Moveable components (slides) within a die can also lead to parting line shift. Mechanical locks
used to hold the slide in place during the injection of the metal can introduce a force that induces
a parting line shift in the direction of the pull of the slide.
The type of die will also affect parting line shift. Due to their design for inter-changeability, unit
dies will inherently experience greater parting line shift than full size dies. If parting line shift is
deemed critical during part design, a full size die should be considered rather than a unit die.
Steps can be taken during the part design stage to minimize the impact of parting line shift.
Datum structures should be set with all of the datum features in one half of the die. If this is
not possible, additional tolerance may need to be added (see Geometric Dimensioning, Section
5). Another consideration during part design is to adjust parting lines so those features where
mismatch is critical are cast in one half of the die.
Steps can also be taken during the die design to minimize parting line shift. Interlocks and
guide blocks can be added to dies to improve alignment, but result in a higher maintenance tool.
Placement of the cavities in the die can also be used to minimize the effect of mismatch between
the two die halves.
Die wear and alignment system wear may impact parting line shift. As components wear,
there is increasing lateral movement that will directly impact parting line shift. The method for
decreasing wear induced parting line shift is to minimize moving parts when designing a die
system, provide good cooling and lubrication, and have a good preventive maintenance program.
It is important to note that parting line shift can occur at any time and its tolerance consequences should be discussed with the die caster at the design stage to minimize its impact on the
final die casting.
There are two components to calculate the affect of parting line shift on a part. The first
component is to determine Linear Tolerance. Linear Tolerance is obtained from table S/P-4A-1
which was discussed earlier in this section. The second component is to determine Parting Line
Shift Tolerance. Cavity area at the parting line is used to determine Projected Area Tolerance
from table S-4A-6.
Parting Line Shift Tolerance is added to the Linear Tolerance to obtain the volumetric affect
of total Parting Line Shift Tolerance on the part.
Parting Line Shift Tolerance is added to other feature tolerances to determine overall part tolerance.
Note that the tolerances in the table apply to a single casting regardless of the number of cavities.
Parting Line Shift Tolerances

are specified as standard
tolerances, only. If a higher
degree of precision is
required, the caster should be
consulted for possible steps
that can be taken.
Parting Line Shift Tolerance
is only specified in Standard
Tolerance because this is
the lowest limit to meet the
requirements of form, fit and
function at the most economical value. Parting line
variation has a compounding
affect on feature tolerances
across the parting line.
4A
4A-19
NADCA
S-4A-6-15
STANDARD
TOLERANCES
Parting Line Shift: Standard Tolerance

Example:
Parting Line
Shift Tolerance
The cavity area at
the parting line is
75 inches squared.
From Table S-4A-6,
the Projected Area
Parting Line Shift
Tolerance is 0.006
(0,152 mm). This is
added to the Linear
Tolerance from table
S/P-4A-1.
Table S-4A-6: Parting Line Shift Tolerance (Excluding unit dies)
Table SP-4-6 Parting Line Shift Tolerance
(excluding unit dies)

inches 2 (cm 2)
inches (mm)
up to 50 in 2
(322.6 cm 2)
.004
(.102 mm)
51 in 2 to 100 in 2
(329.0 cm 2 to 645.2 cm 2)
.006
(.152 mm)
101 in 2 to 200 in 2
(651.6 cm 2 to 1290.3 cm 2)
.008
(.203 mm)
201 in 2 to 300 in 2
(1296.8 cm 2 to 1935.5 cm 2)
.011
(.279 mm)
301 in 2 to 500 in 2
(1941.9 cm 2 to 3225.8 cm 2)
.016
(.406 mm)
501 in 2 to 800 in 2
(3232.3 cm 2 to 5161.3 cm 2)
.020
(.508 mm)
801 in 2 to 1200 in 2
(5167.7 cm 2 to 7741.9 cm 2)
.025
(.635 mm)
Parting Line Shift Tolerance

0.03
Tolerance in Inches
0.025
PL Shift Tolerance
0.02
0.015
0.01
0.005
0
50
(322.6)
100
(645.2)
200
(1290.3)
300
(1935.5)
500
(3225.8)
800
(5161.3)
4A-20
1200
(7741.9)
NADCA
S-4A-7-15
STANDARD
TOLERANCES
Draft Requirements: Standard Tolerances

Draft is the amount of taper or slope given to cores or other parts of the die cavity to permit easy
ejection of the casting.
All die cast surfaces which are normally perpendicular to the parting line of the die require
draft (taper) for proper ejection of the casting from the die. This draft requirement, expressed as
an angle, is not constant. It will vary with the type of wall or surface specified, the depth of the
surface and the alloy selected.
Draft values from the equations at right, using the illustration and the table below, provides
Standard Draft Tolerances for draft on inside surfaces, outside surfaces and holes, achievable
under normal production conditions.
Draft Example (Standard Tolerances):

In the case of an inside surface for an aluminum cast part, for which the constant C is 30 (6
mm), the recommended Standard Draft at three depths is:
Draft
Distance
Draft
Angle
in. (mm)
in. (mm)
Degrees
0.1
(2.50)
0.010 (0.250)
1.0 (25)
0.033 (0.840)
1.9
5.0 (127)
0.075 (1.890)
0.85
To achieve lesser draft than

normal production allows,
Precision Tolerances maybe
specified (see opposite page).
Calculation for
Draft Distance
Calculation
for Draft Angle
D= L
C
D
L
A=
0.01746
Where:
Depth
OR
57.2738
C L
D= Draft in inches
L= Depth or height of feature from the parting line
C= Constant, from table S-4A-7, is based on the type of feature
and the die casting alloy
A= Draft angle in degrees Draft
The formula for draft shown

here represents Standard
Tolerance, or normal casting
most economical level. For
Precision Tolerance for draft,
see the facing page.
Note:
As the formula indicates,
draft, expressed as an angle,
decreases as the depth of the
feature increases. Twice as
much draft is recommended
for inside walls or surfaces
as for outside walls/surfaces.
This provision is required
because as the alloy solidifies it shrinks onto the die
features that form inside
surfaces (usually located in
the ejector half) and away
from features that form
outside surfaces (usually
located in the cover half).
Note also that the resulting draft calculation does
not apply to cast lettering,
logotypes or engraving.
Such elements must be
examined individually as to
style, size and depth desired.
Draft requirements need to
be discussed with the die
caster prior to die design for
satisfactory results.
Drawing defines draft

dimensions for interior
and exterior surfaces
and total draft for holes
(draft is exaggerated for
illustration).
4A-21
4A
NADCA
S-4A-7-15
STANDARD
TOLERANCES
Draft Requirements: Standard Tolerances

Table S-4A-7: Draft Constants for Calculating Draft and Draft Angle
Values of Constant "C" by Features and Depth (Standard Tolerances)
Alloy
Inside Wall
For Dim. in
inches (mm)
Outside Wall
For Dim. in
inches (mm)
Hole, Total Draft

for Dim. in
inches (mm)
Zinc/ZA
50 (9.90 mm)
100 (19.80 mm)
34 (6.75 mm)
Aluminum
30 (6.00 mm)
60 (12.00 mm)
20 (4.68 mm)
Magnesium
35 (7.00 mm)
70 (14.00 mm)
24 (4.76 mm)
Copper
25 (4.90 mm)
50 (9.90 mm)
17 (3.33 mm)
It is not common practice to specify draft separately for each feature. Draft is normally
specified by a general note with exceptions called out for individual features. The formula should
be used to establish general draft requirements with any exceptions identified.
For example, an aluminum casting with most features at least 1.0 in. deep can be covered with a
general note indicating 2 minimum draft on inside surfaces and 1 minimum on outside surfaces
(based on outside surfaces requiring half as much draft).
* For tapped holes cored with removable core pins for subsequent threading see page 4A-34 through 4A-38.
4A-22
NADCA
P-4A-7-15
PRECISION
TOLERANCES
Draft Requirements: Precision Tolerances

All cast surfaces normally perpendicular to the parting line of the die require draft (taper) for
proper ejection of the casting from the die. Minimum precision draft for inside walls is generally
recommended at 3/4 degrees per side; with outside walls requiring half as much draft.
Draft values from the equation at right, using the illustration and the table below, estimate
specific Precision Draft Tolerances for draft on inside surfaces, outside surfaces and holes.
Precision Draft Tolerances will vary with the type of wall or surface specified, the depth of the
wall, and the alloy selected.
Draft Example (Precision Tolerances):

In the case of an inside surface for an aluminum cast part, for which the constant C is 40 (7.80
mm), the recommended Precision Draft at three depths is:
Draft
Distance
Draft
Angle
in. (mm)
in. (mm)
Degrees
0.1 (2.50)
0.006 (0.150)
3.6
1.0 (25)
0.020 (0.510)
1.1
2.5 (63.50)
0.032 (1.140)
0.72
To achieve lesser draft than

normal production allows,
Precision Tolerances maybe
specified (see opposite page).
Calculation for
Draft Distance
D=
Where:
L x 0.8
C
Calculation
for Draft Angle
A=
Depth
D
L
0.01746
or
45.819
C L
D= Draft in inches
L= Depth or height of feature from the parting line
C= Constant, from table P-4A-7, is based on the type of
feature and the die casting alloy
A= Draft angle in degrees Draft
Drawing defines draft

dimensions for interior
and exterior surfaces
and total draft for holes
(draft is exaggerated for
illustration).
Precision Tolerances for

draft resulting from the
calculations outlined here
involve extra precision in
die construction and/or special control in production.
only when necessary. Draft
or the lack of draft can
greatly affect castability.
Early die caster consultation will aid in designing
for minimum draft, yet sufficient draft for castability.
Note:
As the formula indicates, draft, expressed
as an angle, decreases as
the depth of the feature
increases. See graphical
representation on the following pages for various
alloys. Twice as much
draft is recommended for
inside walls or surfaces as
for outside walls/surfaces.
This provision is required
because as the alloy
solidifies it shrinks onto
the die features that form
inside surfaces (usually
located in the ejector half)
and away from features
that form outside surfaces
(usually located in the
cover half). Note also that
the resulting draft calculation does not apply to die
cast lettering, logotypes
or engraving. Such elements must be examined
individually as to style,
size and depth desired.
Draft requirements need to
be discussed with the die
caster prior to die design
for satisfactory results.
4A-23
4A
NADCA
P-4A-7-15
PRECISION
TOLERANCES
Draft Requirements: Precision Tolerances

Table P-4A-7: Draft Constants for Calculating Draft and Draft Angle
Values of Constant "C" by Features and Depth (Precision Tolerances)
Alloy
Inside Wall
For Dim. in
inches (mm)
Outside Wall
For Dim. in
inches (mm)
Hole, Total Draft

For Dim. in
inches (mm)
Zinc/ZA
60 (12.00 mm)
120 (24.00 mm)
40 (7.80 mm)
Al/Mg/Cu
40 (7.80 mm)
80 (15.60 mm)
28 (5.30 mm)
It is not common practice to specify draft separately for each feature. Draft is normally
specified by a general note with exceptions called out for individual features. The formula should
be used to establish general draft requirements with any exceptions identified.
For example, an aluminum casting with most features at least 1.0 in. deep can be covered with a general note indicating 1 minimum draft on inside surfaces and 0.5 minimum on outside surfaces (based
on outside surfaces requiring half as much draft).
4A-24
NADCA
S/P-4A-7-15
STANDARD/PRECISION
TOLERANCES
Aluminum Draft
0.2
Standard Inside Wall

Standard Outside Wall
Precision Inside Wall
Precision Outside Wall
Standard Hole
Precision Hole
0.18
0.16
Draft in Inches
0.14
0.12
0.1
0.08
0.06
0.04
4A
0.02
(2
28
.6
)
10
(2
54
.0
)
11
(2
79
.4
)
12
(3
04
.8
)
(2
03
.2
)
(1
77
.8
)
(1
52
.4
)
(1
27
.0
)
(1
01
.6
)
(7
6.
2)
(5
0.
8)
(2
5.
4)
Length from Parting Line in Inches (mm)
Aluminum Draft Angle

3.5
2.5

Standard Hole
Precision Hole
1.5
1
0.5
)
04
.8
(3
12
(2
11
(2
79
.4
54
.0
.6
)
10
(2
28
.2
)
9
(2
77
(1
03
.8
)
.4
)
7
(1
52
.0
)
6
(1
5
(1
01
27
.6
)
2)
4
(7
6.
8)
0.
(5
(2
5.
4)
Draft Angle in Degrees
4A-25
NADCA
S/P-4A-7-15
STANDARD/PRECISION
TOLERANCES
Copper Draft
0.25
Standard Hole
Precision Hole
Draft in Inches
0.2
0.15
0.1
0.05
(2
28
.6
)
10
(2
54
.0
)
11
(2
79
.4
)
12
(3
04
.8
)
(2
03
.2
)
(1
77
.8
)
(1
52
.4
)
(1
27
.0
)
(1
01
.6
)
(7
6.
2)
(5
0.
8)
(2
5.
4)
Copper Draft Angle
3.5

2.5
Standard Hole
Precision Hole
2
1.5
1
0.5
(2
28
.6
)
10
(2
54
.0
)
11
(2
79
.4
)
12
(3
04
.8
)
(2
03
.2
)
(1
77
.8
)
(1
52
.4
)
(1
27
.0
)
(1
01
.6
)
(7
6.
2)
(5
0.
8)
(2
5.
4)
4A-26
NADCA
S/P-4A-7-15
STANDARD/PRECISION
TOLERANCES
Magnesium Draft
0.16

Standard Hole
Precision Hole
0.14
Draft in Inches
0.12
0.1
0.08
0.06
0.04
4A
0.02
(2
28
.6
)
10
(2
54
.0
)
11
(2
79
.4
)
12
(3
04
.8
)
(2
03
.2
)
(1
77
.8
)
(1
52
.4
)
(1
27
.0
)
(1
01
.6
)
(7
6.
2)
(5
0.
8)
(2
5.
4)
Magnesium Draft Angle

Standard Hole
Precision Hole
1.5
1
0.5
)
(3
04
.8
12
(2
79
.4
)
11
(2
54
.0
10
(2
28
.6
)
9
(2
03
.2
(1
77
.8
)
7
(1
52
.4
(1
27
.0
)
5
(1
01
.6
(7
6.
2)
(5
0.
8)
(2
5.
4)
2.5
4A-27
NADCA
S/P-4A-7-15
STANDARD/PRECISION
TOLERANCES
Zinc Draft
0.12

Standard Hole
Precision Hole
Draft in Inches
0.1
0.08
0.06
0.04
0.02
(1
52
.4
)
7
(1
77
.8
)
8
(2
03
.2
)
9
(2
28
.6
)
10
(2
54
.0
)
11
(2
79
.4
)
12
(3
04
.8
)
(1
27
.0
)
(1
01
.6
)
(7
6.
2)
(5
0.
8)
(2
5.
4)
Zinc Draft Angle

1.8
1.6
1.4

1.2
Standard Hole
Precision Hole
0.8
0.6
0.4
0.2
(2
54
.0
)
11
(2
79
.4
)
12
(3
04
.8
)
.6
)
10
(2
28
.2
)
9
(2
03
.8
)
8
(1
77
7
.4
)
(1
52
.0
)
(1
27
.6
)
(1
01
.2
)
(7
6
.8
)
(5
0
(2
5
.4
)
4A-28
NADCA
S-4A-8-15
STANDARD
TOLERANCES
Flatness Requirements: Standard Tolerance

Flatness defines surface condition not part thickness. See the flatness explanation on the opposite page.
Standard Tolerance is calculated using the largest dimensions defining the area where the
tolerance is to be applied. If flatness is to be determined for a circular surface such as the top
of a can, the largest dimension is the diameter of the can. If flatness is to be determined for a
rectangular area, the largest dimension is a diagonal.
For greater accuracy, see Precision Tolerances for flatness on the opposite page.
Example: Flatness Tolerance - Diagonal

For a part where the diagonal measures 10 inches (254 mm), the maximum Flatness Standard
Tolerance from table S-4A-8 is 0.008 inches (0.20 mm) for the first three inches (76.2 mm) plus
0.003 inches (0.08 mm) for each of the additional seven inches for a total Flatness Standard
Tolerance of 0.029 inches (0.76 mm).
Table S-4-8 Flatness Tolerances, As-Cast: All Alloys
Maximum Dimension
of Die Cast Surface
Tolerance
inches (mm)
up to 3.00 in.
(76.20 mm)
0.008
(0.20 mm)
Additional tolerance,
in. (25.4 mm) for each additional in. (25.4 mm)
0.003
(0.08 mm)
Flatness Example
Flatness Example
The flatness values shown

here represent Standard
Tolerances, or normal casting production practice at
the most economical level.
For greater casting accuracy see Precision Tolerances for this characteristic
on the facing page.
Flatness is described in
detail in Section 5, Geometric Dimensioning &
Tolerancing. Simply put,
Flatness Tolerance is the
amount of allowable surface variation between two
parallel planes which define
the tolerance zone. See the
figures below.
Flatness of a continuous
plane surface on a casting
should be measured by a
method mutually agreed
upon by the designer, die
caster and the customer
before the start of die design.
Note:
The maximum linear dimension is the diameter of a circular surface or the diagonal
of a rectangular surface.
Flatness Design
Guidelines:
1. All draft on walls,
bosses and fins
surrounding and underneath flat surfaces
should be standard
draft or greater.
2. Large bosses or cross
sections can cause
sinks and shrinkage
distortions and should
be avoided directly
beneath flat surfaces.
3. Changes in cross
section should be
gradual and well filleted to avoid stress and
shrinkage distortions.
4. Symmetry is important
to obtain flatness.
Lobes, legs, bosses and
variations in wall height
can all affect flatness.
Explanation
Explanation
4A-29
4A
NADCA
P-4A-8-15
PRECISION
TOLERANCES
for flatness shown represent
involving extra precision in
die construction. They should
where necessary since additional cost may be involved.
Notes:
The maximum linear dimension is the diameter of a circular surface or the diagonal
of a rectangular surface.
Flatness Design
Guidelines:
1. All draft on walls,
bosses and fins
surrounding and
underneath flat surfaces
should be standard draft
or greater.
2. Large bosses or cross
sections can cause sinks
and shrinkage distortions
and should be avoided
directly beneath flat
surfaces.
3. Changes in cross section
should be gradual and
well filleted to avoid
stress and shrinkage
distortions.
4. Symmetry is important
to obtain flatness.
Lobes, legs, bosses and
variations in wall height
can all affect flatness.
Flatness Requirements: Precision Tolerance

The values shown for Precision Tolerance for flatness represent greater casting accuracy involving
extra steps in die construction and additional controls in production. They should be specified
only when and where necessary since additional costs may be involved.
Even closer tolerances may be held by working with the die caster to identify critical zones of
flatness. These areas may be amenable to special die construction to help maintain flatness.
Flatness Explanation
As noted in the explanation diagram, at the bottom of the page, flatness is independent of all
other tolerance features including thickness.
Part thickness has a nominal thickness of 0.300 0.010. Flatness Tolerance is 0.005. Therefore
at the high limit thickness the part surface flatness can be between 0.305 and 0.310. Nominal
thickness flatness can be between .2975 and .3025. Low limit thickness flatness can be between
0.290 and 0.295. Flatness can not range between 0.290 and 0.310. Using both high and low
thickness in combination with flatness defeats the purpose for specifying flatness.
Example: Flatness Tolerance - Diagonal

For a part where the diagonal measures 10 inches (254 mm), the maximum Flatness Precision
Tolerance from table P-4A-8 is 0.005 inches (0.13 mm) for the first three inches (76.2 mm) plus
0.002 inches (0.05 mm) for each of the additional seven inches for a total Flatness Standard
Tolerance of 0.019 inches (0.48 mm).
Table P-4A-8 Flatness Precision Tolerance
Maximum Dimension
of Die Cast Surface
Tolerance
inches (mm)
up to 3.00 in.
(76.20 mm)
0.005
(0.13 mm)
Additional tolerance,
in. (25.4 mm) for each additional in. (25.4 mm)
0.002
(0.05 mm)
Flatness Tolerance
0.05
Standard Tolerance Zone

Precision Tolerance Zone
0.045
0.04
0.035
0.03
0.025
0.02
0.015
0.01
0.005
0
3
(76.2)
4
(101.6)
5
(127.0)
Explanation Diagram
.005 TOL ZONE
4A-30
7
(177.8)
8
(203.2)
9
(228.6)
10
(254.0)
11
(279.4)
Tolerance Zone in Inches (mm)
.005 TOL ZONE

.310
PART AT HIGH
SIZE LIMIT
6
(152.4)
.005 TOL ZONE

.300
PART AT
NOMINAL SIZE
.290
PART AT LOW
SIZE LIMIT
12
(304.8)

Design Recommendations: Cored Holes As-Cast
Cored holes in die castings can be categorized according to their function. There are three
major classifications.
Metal savers
Clearance holes
Function/locating holes
Each of these functions implies a level of precision. Metal savers require the least precision;
function/locating holes require the greatest precision. Leaving clearance holes in-between.
Specifications for cored holes are the combination of form, size and location dimensions and
tolerances required to define the hole or opening.
Metal Savers
Metal savers are cored features, round or irregular, blind or through the casting, whose primary
purpose is to eliminate or minimize the use of raw material (metal/alloy). The design objective
of the metal saver is to reduce material consumption, while maintaining uniform wall thickness,
good metal flow characteristics, good die life characteristics with minimal tool maintenance.
In the design of ribs and small metal savers the designer needs to be aware to avoid creating
small steel conditions in the tool that can be detrimental to tool life.
4A
Design recommendation:
1. Wall thickness
Design for uniform wall thickness around metal savers. Try to maintain wall thickness within 10%
of the most typical wall section.
2. Draft
Use draft constant per NADCA S-4A-7 for inside walls. Keep walls as parallel as practical.
3. Radii/fillets
Use as large a radius as possible, consistent with uniform wall thickness. Refer to NADCA guidelines
G-6-2. Consider 0.06 inch radius (1.5 mm radius) as a minimum. A generous radius at transitions
and section changes will promote efficient metal flow during cavity filling.
Clearance Holes
Clearance holes are cored holes, round or irregular, blind or through the casting, whose primary
purpose is to provide clearance for features and components. Clearance implies that location of
the feature is important.
1. Tolerance
Dimensions locating the cored hole should be per NADCA Standard tolerances; S-4A-1
Linear Dimension, S-4A-2 Parting Line Dimensions and S-4A-3 Moving Die Components.
2. Wall thickness
Design for uniform wall thickness around clearance holes. Try to maintain wall thickness
within 10% of the most typical wall section. If hole is a through hole, allowance should be
made for any trim edge per NADCA G-6-5, Commercial Trimming within 0.015 in. (0.4 mm).
3. Draft
Use draft constant per NADCA S-4A-7 for inside walls. Keep walls as parallel as practical.
4. Radii/fillets
Use as large a radius as possible, consistent with uniform wall thickness. Refer to NADCA
guidelines G-6-2. Consider 0.06 inch radius (1.5 mm radius.) as a minimum. A generous
radius at transitions and section changes will promote efficient metal flow during cavity filling.
4A-31

For holes with less than a
0.25 inch diameter, wall
stock may be a minimum of
one half the hole diameter. Unless wall thickness
is required for strength.
However, Ribbing Should be
applied first.
For holes with larger than a
0.25 inch diameter, the wall
stock shall be the nominal
wall thickness (subject to
part design).
These rules can be broken
if the product requires more
strength. However, ribbing
should be attempted first.
Functional/Locating Holes
Functional/locating holes are cored holes whose purpose is to provide for a functional purpose
such as threading, inserting and machining or location and alignment for mating parts or
secondary operations.
1. Tolerance
Dimensions locating the cored hole to be per NADCA Precision tolerances; P-4A-1 Linear
Dimension, P-4A-2 Parting Line Dimensions and P-4A-3 Moving Die Components.
2. Wall thickness
Design for uniform wall thickness around functional/locating holes. Try to maintain wall
thickness within 10% of the most typical wall section. If hole is a through hole, allowance
should be made for any trim edge per NADCA G-6-5, Commercial Trimming within 0.015
inch (0.4 mm) or if this is not acceptable, a mutually agreed upon requirement.
3. Draft
Use draft constant per NADCA P-4A-7 for inside walls. Keep walls as parallel as practical.
4. Radii/fillets
Use as large a radius as possible, consistent with uniform wall thickness. Refer to NADCA
guidelines G-6-2. Consider 0.03 inch radius (0.8 mm radius.) as a minimum. A generous
radius at transitions and section changes will promote efficient metal flow during cavity filling.
Other Design Considerations

Hole depths
Diameter of Hole Inches
1/8 5/32
3/16 1/4 3/8 1/2 5/8 3/4 1
Alloy
Maximum Depth Inches
Zinc
3/8 9/16 3/4 1 1-1/2 2 3-1/8

4-1/2 6
Aluminum
5/16 1/2 5/8 1 1-1/2 2 3-1/8

4-1/2 6
Magnesium 5/16 1/2 5/8 1 1-1/2 2 3-1/8

4-1/2 6
Copper 1/2 1 1-1/4 2 2-1/2 5
Note:
The depths shown are not applicable under conditions where small diameter cores are widely
spaced and, by design, are subject to full shrinkage stress.
Perpendicularity
See Section 5 pages 5-19 and 5-20 Orientations Tolerances.
4A-32
4A
4A-33
NADCA
S-4A-9-15
STANDARD
TOLERANCES
normal casting production
practice at the most economical level. For greater casting
accuracy see Precision Tolerances for the characteristic
on the facing page.
Cored Holes for Cut Threads: Standard Tolerances

Cored holes for cut threads are cast holes that require threads to be cut (tapped) into the metal.
The table below provides the dimensional
tolerances for diameter, depth and draft
X
Tip or
for each specified thread type (Unified and
Y
Spherical
Metric Series). When required, cored holes in
Radius
Al, Mg, Zn and ZA may be tapped without
Optional
removing draft. This Standard Tolerance
D1
D2
recommendation is based on allowing 85%
of full thread depth at the bottom D2 (small
end) of the cored hole and 55% at the top D1
(large end) of the cored hole. A countersink or radius is also recommended at the top of the cored
hole. This provides relief for any displaced material and can also serve to strengthen the core.
Threads extend through the cored hole as by Y. X shows the actual hole depth. As with the
countersink at the top of the hole, the extra hole length provides relief for displaced material and
allows for full thread engagement. Tolerances below apply to all alloys.
Table S-4A-9: Cored Holes for Cut Threads (Standard Tolerances) Unified Series and Metric Series
Table S-4A-9 Cored Holes for Cut Threads (Standard Tolerances) Unified Series and Metric Series
Unified
Series/
Class
Hole Diameter
D 1, Max. D 2, Min.
Thread Depth
Y, Max.
Hole Depth
X, Max.
inches
inches
inches
6-32, UNC/2B, 3B
0.120
inches
0.108
0.414
0.508
6-40, UNF/2B
8-32, UNC/2B
8-36, UNF/2B
10-24, UNC/2B
10-32, UNF/2B
12-24, UNC/2B
12-28, UNF/2B
1/4A-20, UNC/1B, 2B
1/4A-28, UNF/1B, 2B
5/16-18, UNC/1B, 2B
5/16-24, UNF/1B, 2B
3/8-16, UNC/1B, 2B
3/8-24, UNF/1B, 2B
7/16-14, UNC/1B, 2B
7/16-20, UNF/1B, 2B
1/2-13, UNC/1B, 2B
1/2-20, UNF/1B, 2B
9/16-12, UNC/1B, 2B
9/16-18, UNF/1B, 2B
5/8-11, UNC/1B, 2B
5/8-18, UNF/1B, 2B
3/4A-10, UNC/1B, 2B
3/4A-16, UNF/1B, 2B
7/8- 9, UNC/1B, 2B
7/8-14, UNF/1B, 2B
1- 8, UNC/1B, 2B
1-12, UNF/1B. 2B
0.124
0.146
0.148
0.166
0.172
0.192
0.196
0.221
0.230
0.280
0.289
0.339
0.351
0.396
0.409
0.455
0.471
0.514
0.530
0.572
0.593
0.691
0.714
0.810
0.833
0.927
0.951
0.114
0.134
0.137
0.151
0.160
0.177
0.182
0.203
0.216
0.260
0.273
0.316
0.336
0.371
0.390
0.428
0.453
0.485
0.510
0.540
0.573
0.657
0.691
0.772
0.808
0.884
0.922
0.345
0.492
0.410
0.570
0.475
0.648
0.540
0.750
0.500
0.781
0.625
0.938
0.656
1.094
0.766
1.250
0.750
1.406
0.844
1.563
0.781
1.688
0.938
1.750
1.094
2.000
1.250
0.420
0.586
0.493
0.695
0.569
0.773
0.647
0.900
0.607
0.948
0.750
1.125
0.781
1.308
0.916
1.481
0.900
1.656
1.010
1.835
0.948
1.988
1.125
2.083
1.308
2.375
1.500
Metric
Series
Thread
Size
Hole Diameter
D 1, Max.
D 2, Min.
Thread Depth
Y, Max.
Hole Depth
X, Max.
mm
mm
mm
mm
M3.5 X 0.6
M4 X 0.7
M5 X 0.8
M6 X 1
M8 X 1.25
f M8 X 1
M10 X 1.5
f M10 X 0.75
f M10 X 1.25
M12 X 1.75
f M12 X 1
f M12 X 1.25
M14 X 2
fM14 X 1.5
f M15 X 1
M16 X 2
f M16 X 1.5
f M17 X 1
f M18 X 1.5
M20 X 2.5
f M20 X 1
f M20 X 1.5
f M22 X 1.5
M24 X 3
f M24 X 2
f M25 X 1.5
f M27 X 2
3.168
3.608
4.549
5.430
7.281
7.430
9.132
9.578
9.281
10.983
11.430
11.281
12.834
13.132
14.430
14.834
15.132
16.430
17.132
18.537
19.430
19.132
21.132
22.239
22.834
24.132
25.834
2.923
3.331
4.239
5.055
6.825
7.055
8.595
9.285
8.825
10.365
11.055
10.825
12.135
12.595
14.055
14.135
14.595
16.055
16.595
17.675
19.055
18.595
20.595
21.215
22.135
23.595
25.135
7.88
9.00
11.25
13.50
18.00
14.00
22.50
10.00
20.00
27.00
15.00
18.00
31.50
24.50
15.00
32.00
24.00
15.30
24.30
40.00
15.00
25.00
25.30
48.00
30.00
25.00
33.75
9.68
11.10
13.65
16.50
21.75
17.00
27.00
12.25
23.75
32.25
18.00
21.75
37.50
29.00
18.00
38.00
28.50
18.30
28.80
47.50
18.00
29.50
29.80
57.00
36.00
29.50
39.75
M30 X 3.5
27.941
26.754
60.00
70.50
f = Fine Pitch Series
4A-34
NADCA
P-4A-9-15
PRECISION
TOLERANCES
Cored Holes for Cut Threads: Precision Tolerances

Cored holes for cut threads are cast holes that
require threads to be cut (tapped) into the
X
Tip or
metal. The table below provides the dimensional
Y
Spherical
tolerances for diameter, depth and draft for
Radius
each specified thread type (Unified and Metric
Optional
D1
D2
Series). When required, cored holes in Al, Mg,
Zn and ZA may be tapped without removing
draft. This Precision Tolerance recommendation
is based on allowing 95% of full thread depth at
the bottom D2 (small end) of the cored hole and the maximum minor diameter at the top D1 (large
end) of the cored hole. A countersink or radius is also recommended at the top of the cored hole. This
provides relief for any displaced material and can also serve to strengthen the core.

involving extra precision
in die construction and/or
only when and where necessary, since additional cost
may be involved.
4A
Table P-4A-9: Cored Holes for Cut Threads (Precision Tolerances) Unified Series and Metric Series
Table P-4A-9 Cored Holes for Cut Threads (Precision Tolerances) Unified Series and Metric Series
Unified
Series/
Class
0-80, UNF/2B, 3B
1-64, UNC/2B, 3B
1-72, UNF/2B, 3B
2-56, UNC/2B, 3B
2-64, UNF/2B, 3B
3-48, UNC/2B, 3B
3-56, UNF/2B, 3B
4A-40, UNC/2B, 3B
4A-48, UNF/2B, 3B
5-40, UNC/2B, 3B
5-44, UNF/2B, 3B
6-32, UNC/2B, 3B
6-40, UNF/2B
8-32, UNC/2B
8-36, UNF/2B
10-24, UNC/2B
10-32, UNF/2B
12-24, UNC/2B
12-28, UNF/2B
1/4A-20, UNC/1B, 2B
1/4A-28, UNF/1B, 2B
5/16-18, UNC/1B, 2B
5/16-24, UNF/1B, 2B
3/8-16, UNC/1B, 2B
3/8-24, UNF/1B, 2B
7/16-14, UNC/1B, 2B
7/16-20, UNF/1B, 2B
1/2-13, UNC/1B, 2B
1/2-20, UNF/1B, 2B
9/16-12, UNC/1B, 2B
9/16-18, UNF/1B, 2B
5/8-11, UNC/1B, 2B
5/8-18, UNF/1B, 2B
3/4A-10, UNC/1B, 2B
3/4A-16, UNF/1B, 2B
7/8- 9, UNC/1B, 2B
7/8-14, UNF/1B, 2B
1- 8, UNC/1B, 2B
1-12, UNF/1B. 2B
Hole Diameter
D 1, Max. D 2, Min.
Thread Depth
Y, Max.
inches
inches
inches
(0.051)
(0.062)
(0.064)
(0.074)
(0.075)
(0.085)
(0.087)
(0.094)
(0.097)
0.106
0.108
0.114
0.119
0.139
0.142
0.156
0.164
0.181
0.186
0.207
0.220
0.265
0.277
0.321
0.340
0.376
0.395
0.434
0.457
0.490
0.515
0.546
0.578
0.663
0.696
0.778
0.814
0.890
0.928
(0.047)
(0.057)
(0.059)
(0.068)
(0.070)
(0.078)
(0.081)
(0.086)
(0.091)
0.099
0.102
0.106
0.112
0.132
0.135
0.147
0.158
0.173
0.179
0.199
0.213
0.255
0.270
0.311
0.332
0.364
0.386
0.421
0.449
0.477
0.505
0.532
0.568
0.647
0.686
0.761
0.802
0.871
0.914
(0.130)
(0.200)
(0.160)
(0.240)
(0.200)
(0.280)
(0.220)
(0.320)
(0.240)
0.280
0.240
0.350
0.270
0.290
0.260
0.390
0.240
0.340
0.270
0.370
0.270
0.440
0.310
0.470
0.340
0.570
0.400
0.640
0.370
1.280
0.880
1.430
0.930
1.590
0.950
1.750
1.200
1.900
1.340
Hole Depth
X, Max.
Metric
Series
Thread
Size
Hole Diameter
D 1, Max.
D 2, Min.
Thread Depth
Y, Max.
Hole Depth
X, Max.
mm
mm
mm
mm
(0.163)
(0.250)
(0.200)
(0.300)
(0.250)
(0.350)
(0.275)
(0.400)
(0.300)
0.350
0.300
0.438
0.338
0.363
0.325
0.488
0.300
0.425
0.338
0.463
0.338
0.550
0.388
0.588
0.425
0.713
0.500
0.800
0.463
1.600
1.100
1.788
1.163
1.988
1.188
2.188
1.500
2.375
1.675
M1.6 X 0.35
M2 X 0.4
M2.5 X 0.45
M3 X 0.5
M3.5 X 0.6
M4 X 0.7
M5 X 0.8
M6 X 1
M8 X 1.25
f M8 X 1
M10 X 1.5
f M10 X 0.75
M10 X 1.25
M12 X 1.75
f M12 X 1
f M12 X 1.25
M14 X 2
f M14 X 1.5
f M15 X 1
M16 X 2
f M16 X 1.5
f M17 X 1
f M18 X 1.5
M20 X 2.5
f M20 X 1
f M20 X 1.5
f M22 X 1.5
M24 X 3
f M24 X 2
f M25 X 1.5
f M27 X 2
M30 X 3.5
(1.32)
(1.68)
(2.14)
(2.60)
2.99
3.42
4.33
5.15
6.91
7.15
8.68
9.38
8.91
10.44
11.15
10.91
12.21
12.68
14.15
14.21
14.68
16.15
16.68
17.74
19.15
18.68
20.68
21.25
22.21
23.68
25.21
26.71
(1.24)
(1.59)
(2.04)
(2.49)
2.88
3.28
4.17
4.96
6.70
6.96
8.44
9.23
8.70
10.17
10.96
10.70
11.91
12.44
13.96
13.91
14.44
15.96
16.44
17.38
18.96
18.44
20.44
20.85
21.91
23.44
24.91
26.31
(2.40)
(3.00)
(3.75)
(4.50)
5.25
6.00
7.50
9.00
12.00
12.00
15.00
12.50
15.00
18.00
15.00
15.00
21.00
21.00
18.75
28.00
24.00
17.00
22.50
30.00
20.00
20.00
22.00
36.00
30.00
25.00
27.00
37.50
(3.45)
(4.20)
(5.10)
(6.00)
7.05
8.10
9.90
12.00
15.75
15.00
19.50
14.75
18.75
23.25
18.00
18.75
27.00
25.50
21.75
34.00
28.50
20.00
27.00
37.50
23.00
24.50
26.50
45.00
36.00
29.50
33.00
48.00
Values in italics and parentheses are achievable but should be discussed with the die caster prior to finalization of a casting design.
4A-35
NADCA
P-4A-10-15
PRECISION
TOLERANCES
Cored holes for formed
threads are specified in die
castings as Precision Tolerances, because they require
The specific diameter, depth
and draft required will determine the added cost.
Note:
Tolerances for cored holes
for thread forming fasteners
(self tapping screws) should
be provided by the manufacturer of the specific type
of thread forming fastener
to be used.
4A-36
Cored Holes for Formed Threads: Precision Tolerances

The Precision Tolerance recommendations for cored holes for formed threads, on the opposite
page, are based on allowing 75% of full thread depth at the bottom D2 (small end) of the cored
hole and 50% at the top D1 (large end) of the cored hole. When required, cored holes in aluminum, zinc and magnesium may be tapped without removing draft.
Cold form taps displace material in an extrusion or swaging process. As a result, threads are
stronger because the material is work hardened as a part of the process for forming threads.
Because material is displaced, a countersink is recommended at the ends of through holes and at
the entry of blind holes.
Tests indicate that thread height can be reduced to 60% without loss of strength, based on the
fact cold formed threads in die castings are stronger than conventional threads. However, the use
of 65% value is strongly recommended.
Since cored holes in castings must have draft (taper), the 65% thread height Y should be at a
depth that is an additional one-half of the required engagement length of the thread in the hole.
Blind holes should be cored deep enough to allow a four (4) thread lead at the bottom of the
hole. This will result in less burr around the hole and longer tool life. Hole sizes of #6 or less, or
metric M3 or less, are recommended for through holes only.
Cold form tapping is not recommended for holes with a wall thickness less than two-thirds
the nominal diameter of the thread.
The Precision Tolerance recommendation should be considered as a starting point with respect
to depth recommendations. There are many applications that do not require the percent of thread
listed here. If a lesser percent of thread can be permitted, this would, in turn, allow more draft
and a deeper hole. Amount and direction of required strength can be determined by testing.
NADCA
P-4A-10-15
PRECISION
TOLERANCES
Cored Holes for Formed Threads: Precision Tolerances

involving extra precision in
since additional cost may
be involved.
The tolerances below apply to AI, Mg, Zn and ZA die casting alloys, as footnoted. Note that,
when required, cored holes in aluminum, zinc, and magnesium may be tapped without removing
draft.
X
Guidelines are provided on the opposite page
Tip or
Y
Spherical regarding thread height, depth, and limitations
Radius
on wall thickness.
D1
D2
Optional
Table
P-4A-10:
Cored
for Formed
Threads
(Precision
Tolerances)
Unified
Series
Metric
Series
Table
P-4A-10
CoreHoles
d Holes
for Formed
Thr
eads
(Precision)
Unified
Series
andand
Metric
Series
Unified
Series
Class
0-80, UNF/2B, 3B
1-64, UNC/2B, 3B
1-72, UNF/2B, 3B
2-56, UNC/2B, 3B
2-64, UNF/2B, 3B
3-48, UNC/2B, 3B
3-56, UNF/2B, 3B
4A-40, UNC/2B, 3B
4A-48, UNF/2B, 3B
5-40, UNC/2B, 3B
5-44, UNF/2B, 3B
6-32, UNC/2B, 3B
6-40, UNF/2B
8-32, UNC/2B
8-36, UNF/2B
10-24, UNC/2B
10-32, UNF/2B
12-24, UNC/2B
12-28, UNF/2B
1/4A-20, UNC/1B, 2B
1/4A-28, UNF/1B, 2B
5/16-18, UNC/1B, 2B
5/16-24, UNF/1B, 2B
3/8-16, UNC/1B, 2B
3/8-24, UNF/1B, 2B
7/16-14, UNC/1B, 2B
7/16-20, UNF/1B, 2B
1/2-13, UNC/1B, 2B
1/2-20, UNF/1B, 2B
9/16-12, UNC/1B, 2B
9/16-18, UNF/1B, 2B
5/8-11, UNC/1B, 2B
5/8-18, UNF/1B, 2B
3/4A-10, UNC/1B, 2B
3/4A-16, UNF/1B, 2B
7/8- 9, UNC/1B, 2B
7/8-14, UNF/1B, 2B
1- 8, UNC/1B, 2B
1-12, UNF/1B, 2B
Hole Diameter
D 1, Max. D 2, Min.
Thread Depth
Y, Max.
Hole Depth
X, Max.
inches
inches
inches
inches
(0.0558)
(0.0677)
(0.0683)
(0.0799)
(0.0807)
(0.0919)
(0.0929)
(0.1035)
(0.1049)
(0.1165)
(0.1173)
(0.1274)
(0.1295)
0.153
0.155
0.176
0.179
0.202
0.204
0.233
0.238
0.294
0.298
0.354
0.361
0.413
0.421
0.474
0.483
0.534
0.544
0.594
0.606
0.716
0.729
0.837
0.851
0.958
0.972
(0.0536)
(0.0650)
(0.0659)
(0.0769)
(0.0780)
(0.0884)
(0.0899)
(0.0993)
(0.1014)
(0.1123)
(0.1134)
(0.1221)
(0.1253)
0.148
0.150
0.169
0.174
0.195
0.198
0.225
0.232
0.284
0.291
0.343
0.354
0.401
0.412
0.461
0.475
0.520
0.534
0.579
0.597
0.699
0.718
0.818
0.839
0.936
0.958
(0.090)
(0.110)
(0.110)
(0.129)
(0.129)
(0.149)
(0.149)
(0.168)
(0.168)
(0.188)
(0.188)
(0.207)
(0.207)
0.328
0.328
0.380
0.380
0.432
0.432
0.500
0.500
0.703
0.703
0.844
0.844
0.984
0.984
1.125
1.125
1.266
1.266
1.406
1.406
1.500
1.500
1.750
1.750
2.000
2.000
(0.120)
(0.146)
(0.146)
(0.172)
(0.172)
(0.198)
(0.198)
(0.224)
(0.224)
(0.250)
(0.250)
(0.276)
(0.276)
0.492
0.492
0.570
0.570
0.648
0.648
0.750
0.750
0.938
0.938
1.125
1.125
1.313
1.313
1.500
1.500
1.688
1.688
1.875
1.875
2.250
2.250
2.625
2.625
3.000
3.000
Metric
Series
Thread
Size
Hole Diameter
D 1, Max.
D 2, Min
Thread Depth
Y, Max.
Hole Depth
X, Max.
mm
mm
mm
mm
M1.6 X 0.35
M2 X 0.4
M2.5 X 0.45
M3 X 0.5
M3.5 X 0.6
M4 X 0.7
M5 X 0.8
M6 X 1
M8 X 1.25
f M8 X 1
M10 X 1.5
f M10 X 0.75
fM10 X 1.25
M12 X 1.75
f M12 X 1
f M12 X 1.25
M14 X 2
f M14 X 1.5
f M15 X 1
M16 X 2
f M16 x 1.5
f M17 X 1
f M18 X 1.5
M20 X 2.5
f M20 X 1
f M20 X 1.5
f M22 X 1.5
M24 X 3
f M24 X 2
f M25 X 1.5
f M27 X 2
M30 X 3.5
(1.481)
(1.864)
(2.347)
(2.830)
3.296
3.762
4.728
5.660
7.575
7.660
9.490
9.745
9.575
11.41
11.66
11.58
13.32
13.49
14.66
15.32
15.49
16.66
17.49
19.15
19.66
19.49
21.49
22.98
23.32
24.49
26.32
28.81
(1.422)
(1.796)
(2.271)
(2.745)
3.194
3.643
4.592
5.490
7.363
7.490
9.235
9.618
9.363
11.11
11.49
11.36
12.98
13.24
14.49
14.98
15.24
16.49
17.24
18.73
19.49
19.24
21.24
22.47
22.98
24.24
25.98
28.22
(2.4)
(3.0)
(3.8)
(4.5)
7.0
8.0
10.0
12.0
16.0
16.0
20.0
12.5
20.0
24.0
18.0
18.0
28.0
21.0
18.8
32.0
24.0
17.0
27.0
40.0
20.0
30.0
27.5
48.0
36.0
31.3
40.5
60.0
(3.2)
(4.0)
(5.0)
(6.0)
10.5
12.0
15.0
18.0
24.0
24.0
30.0
30.0
30.0
36.0
36.0
36.0
42.0
42.0
45.0
48.0
48.0
51.0
54.0
60.0
60.0
60.0
66.0
72.0
72.0
75.0
81.0
90.0
Values in italics and parentheses are achievable but should be discussed with the die caster prior to finalization of a casting design.
4A-37
4A
NADCA
S-4A-11-15
STANDARD
TOLERANCES
The values shown for tapered
pipe threads represent Standard Tolerances, or normal
die casting production practice at the most economical
level. N.P.T. threads should
be specified, where possible,
for most efficient production.
Cored Holes for Pipe Threads: Standard Tolerances

Most pipes require taper to ensure that the connections
seal as more of the thread is engaged. For example, when a
X
garden hose is first threaded onto a threaded connection, it
D
is very loose. As more of the thread is engaged by screwing
the hose on, there is less play as the fitting gets tighter. A
good fitting will become tight before the threads bottom
C
out. Additional hole beyond the threads is provided so that
fitting can be tightened against the taper to achieve the
desired seal. Taper also allows for part wear.
There are two pipe thread taper standards. National
45o
Pipe Taper (N.P.T.) is the most common standard. A
fitting should seal with at least one revolution of turn still
available on the thread. The fitting should not bottom out in the hole. Standard taper is normally
inches per foot. However, taper for special applications is determined by required strength
formerly discussed in Cored Holes for Formed Threads.
Aeronautical National Pipe Taper (A.N.P.T.) is basically the same as N.P.T. pipe threads.
However, diameter, taper and thread form are carefully controlled for military and aviation use.
There is an associated cost increase using the A.N.P.T. standard since tighter controls are required.
The cored holes specified below are suitable for both N.P.T. and A.N.P.T. threads. The 1
47 taper per side is more important for A.N.P.T. than N.P.T. threads. There is no comparable
metric standard for pipe threads.
For the most economical die casting production, N.P.T. threads should be specified where
possible. A.N.P.T. threads may require additional steps and cost.
The required taper for all N.P.T. and A.N.P.T. sizes is 1 4710per side.
The differences in measurement of these threads represent the differences in function. The
N.P.T. thread quality in determined by use of the L1 thread plug gauge. This thread is intended
as a tapered sealing thread using pipe dope or another sealing agent to provide a leak tight seal.
The A.N.P.T. thread, as well as the N.P.T.F. (American National Taper Dryseal PressureTight Joints) thread, represents a tapered thread that is capable of sealing without the aid of
sealing agents; thus their identification as dry seal threads. These threads are checked with the
use of an L1 and L3 thread member as well as a six step plug gauge to verify thread performance
on the crests. The difference of the A.N.P.T. and N.P.T.F. is in the tolerance of the gauging. The
dry seal threads are more difficult to cast as the draft angle of the cores must be 1 47 per side
and without drags to avoid lobing at the tapping operation or an L3 failure.
Table
for Tapered
TaperedPipe
PipeThreads
Threads
Both
N.P.T.
A.N.P.T.
TableS-4A-10
S-4A-11:Cored
Cored Holes
Holes for
Both
N.P.T.
andand
A.N.P.T.
Tap size
D Diameter
Minimum Depth X
for Standard Tap
0.245 0.003
0.338 0.003
0.609
0.609
0.455
0.458
0.327
0.421
18
18
0.440 0.003
0.575 0.004
0.859
0.875
0.696
0.702
0.577
0.702
- 14
- 14
0.713 0.004
0.923 0.004
1.109
1.109
0.918
0.925
0.890
1.077
1 - 11 1/2
1 1/4 - 11 1/2
1.160 0.005
1.504 0.006
1.343
1.375
1.101
1.113
1.327
1.656
1 1/2 - 11 1/2
2 - 11 1/2
1.743 0.007
2.217 0.008
1.390
1.375
1.127
1.205
1.921
2.515
2 1/2 - 8
3- 8
2.650 0.008
3.277 0.009
1.953
2.031
1.697
1.780
2.921
3.546
1/16
1/8
- 27
- 27
1/4 3/8 1/2

3/4
4A-38
Minimum Depth X
for Short Projection Tap
C Diameter .020
NADCA
S-4A-12-15
STANDARD
TOLERANCES
Cast Threads
Threads can be cast in aluminum, magnesium, or zinc. Normally, cast threads are confined to
external threads where precision class fits are not required. If a precision class fit is required, the
die caster should be consulted. Secondary machining may be required.
External threads can be formed either across the parting line of a die (fig.1) or with slides (fig.
2). Tolerances shown in Table S-4A-12 reflect the method by which the threads are formed.
The Major diameter shall be in compliance with the specified thread form definition as agreed
upon between the purchaser and the die caster.
Threaded parts are identified by a series of numbers

known as a thread callout. A
typical thread callout may be
1/16-28-0.960-0.580-0.127.02 where:
1/16 is the nominal thread size
28 is the number of Threads
Per Inch (TPI)
Table
Die
Cast
Threads
Tolerances
TableS-4A-12:
S-4A-12
Die
Cast
Threads
Tolerances
Figure 1
Figure 2
Method of Forming
Threads
PL
PL
Aluminum/
Magnesium
Zinc
32
24
32
24
Minimum O.D.
0.187
(4.763 mm)
0.250
(6.350 mm)
0.187
(4.763 mm)
0.250
(6.350 mm)
Tolerance on thread lead per

inch of length
.005
(.127 mm)
.006
(.152 mm)
.005
(.127 mm)
.006
(.152 mm)
Tolerances
Zinc
Minimum
i
pitch or maximum
number of threads per inch
4A
Aluminum/
Magnesium
Minimum
i
Pitch Diameter
.004
.005
.005
.006
(.102 mm)
(.127 mm)
(.127 mm)
(.152 mm)
Tolerance
Notes:
1.
An additional trim or chasing operation may be necessary to remove flash formed between
threads.
2.
Direct tolerances shown should be applied wherever possible rather than specifying thread
class or fit.
3.
The values indicated include parting line, moving die component and linear dimension
tolerances. If tighter tolerances are required, the caster should be consulted.
Figure 3. Design Considerations

The recommended designs for terminating a die cast external thread are shown below:
OR
PL
PL
chamfer
Flats on the thread at the parting line will greatly simplify the trimming operation and result in the most economical means
of producing die cast threads.
LESS DESIRABLE DESIGN
MORE DESIRABLE DESIGN
PL
PARTING LINE
WHEN DIES SHIFT (DUE TO STRESS OR OTHER FACTORS),

THE THREADS WILL NOT BE ALIGNED AND CREATE MORE
PROBLEMS.
4A-39
NADCA
S/P-4A-13-15
STANDARD/PRECISION
TOLERANCES
Machining stock allowances are a function of linear
dimensions tolerances and
parting line tolerances, and
whether Standard or Precision Tolerances are required.
will usually represent greater
control in production. For
economical production, they
when and where necessary.
Note:
No consideration was given
to flatness in the above
examples. The part shape
may dictate a flatness tolerance that exceeds the sum
of the linear and across
parting line tolerances. (See
Flatness Tolerances S-4A-8
and P-4A-8.) Additional
machining would then be
required unless the part
can be straightened prior to
machining.
Machining Stock Allowance (Standard and Precision)

It is important to understand that the optimum mechanical properties and density of a casting
are at or near the surface. If machining is to be performed on a casting, a minimum amount of
material should be removed so as not to penetrate the less dense portion. However, to assure
cleanup, an allowance must be provided for both the machining variables and the casting
variables covered by NADCA Standards in this section.
Datum structure is very important to help minimize or eliminate the effect of these variables.
(See Datum Reference Framework in Geometric Dimensioning, Section 5, for a preferred datum
framework.) Best results are attained if the casting is located from datum points that are in the
same die half as the feature to be machined.
Consulting with your caster early will help minimize the effect of tolerance accumulation and
unnecessary machining.
Normal minimum machining allowance is 0.010 in. (0.25 mm) to avoid excessive tool wear
and minimize exposure of porosity. The maximum allowance is the sum of this minimum, the
machining allowance and the casting allowance.
Machine Stock Tolerances
0.25
Min Machine Stock Allowance

Machining Allowance
Linear Casting Allowance
Across Parting Line Precis Tol.
Standard Hole
Precision Hole
Tolerance in Inches
0.2
0.15
0.1
0.05
0
1
(25.4)
4A-40
2
(50.8)
3
4
5
6
7
8
9
10
11
12
(76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Length in Inches (mm)

Machining Stock Allowance (Standard and Precision)
Example:
Assume a 5.00 0.001 in. (127 0.025 mm) finish dimension on an aluminum die cast part that
is 8.00 x 8.00 in. (203.2 x 203.2 mm).
In example A in the table on the facing page, surface to be machined is formed in the same die half as
the datum points. In example B, surface to be machined is formed in the opposite half of the die as the
datum points. Both examples are shown using the Precision Tolerances for linear dimensions and parting
line. The Standard Tolerances for linear dimensions and parting line would utilize the same format.
Machining Stock Allowance Comparative Example: Precision Tolerances

Example A
Example B
Datum Points
Datum Points
In Same Die Half In Opposite Die Half
0.010
Minimum Machine Stock Allowance 0.010
(0.25 mm)
(0.25 mm)
inches (mm)
0.002
0.002
Machining Allowances
(0.05 mm)
(0.05 mm)
( 0.001 in. or 0.026 mm)
0.012
0.012
Linear Casting Allowance
(0.356 mm)
(0.356 mm)
on 5.000 in. (127 mm)
Dimension Precision Tolerance A
0.008
Across Parting Line
(0.020 mm)
Precision Tolerances B
0.026
0.034
Maximum Stock
Casting Dimension C
(0.56 mm)
5.017 0.006
(127.45 0.18 mm)
4A
(0.86 mm)
5.026 +0.014/-0.006
(127.66 +0.38/-0.18 mm)
A 0.007 (0.18 mm) P-4A-1-03 Precision Tolerance

B 0.008 (0.20 mm) P-4A-2 Precision Tolerance
C Casting dimension would not be needed if drawing was a combined drawing, only finish
dimension of 5.00 0.001 in. (127 0.025 mm) would be needed.
4A-41

Additional Considerations for Large Castings
1 Wall Thickness:
1.1: Definition: Wall thickness is the distance between two parallel or nearly parallel
surfaces. Wall thickness may vary depending on the application of draft. Wall thickness
should be maintained as uniform as possible. A general guideline would be to keep the
range of thickness within 2X of the thinnest wall. A second guideline is to keep the wall
as thin as possible to meet the castings functional requirements.
1.2: General: 0.14 (3.5mm (+/- 0.5mm)
1.2.1 Deviations: from the nominal condition are based upon product function and manufacturing process requirements.
2 Radii:
2.1 Fillet Radii:
2.1.1 General: 0.14 (+0.08/-0.04) [3.5mm (+2.0mm/-1.0mm)]
2.1.1.1 Deviations: from the nominal condition are based upon product function and
manufacturing process requirements.
2.1.2 Minimum: 0.060 (1.5mm)
2.2 Corner Radii:

2.2.1 General: 0.060 (+0.08/-0.04) [1.5mm (+2mm/-1mm)]
2.2.1.1 Deviations: from the nominal condition are based upon product function and
manufacturing process requirements.
2.2.2 Minimum: 0.020 (0.5mm)

3 Cores:
3.1 Guidelines: Cores should be used to minimize machining stock, and should be pulled
perpendicular to each other. Use stepped cores where possible to minimize finish stock,
reduce heavy sections, and minimize porosity.
3.2 Minimum: Cored hole diameter to be 0.25 (6.0mm) in and parallel to the direction
of die draw.
3.3 For holes Less Than: 0.50 (12.5mm) diameter the core hole length to diameter (L/D)
ratio should not exceed 4:1.
3.4 For Holes Greater Than: 0.50 (12.5mm) diameter the core pin length to diameter (L/D)
ratio should not exceed 10:1.
4 Bosses:
4.1: Minimize the boss height as much as possible.
4.2: When the height to diameter ratio of the boss exceeds 1, it is recommended that ribs be
used to improve filling.
4.3: Design adjacent bosses with a minimum 0.25 (6.5mm) gap between bosses to
minimize porosity.
4A-42

Additional Considerations for Large Castings
5: Machining Stock:
5.1 General:
5.1.1: Machining stock should be minimized. Because die casting exhibit a skin, the
5.2:
densest fine-grained casting structure is near the surface.

5.1.2: Deviations from nominal condition are based upon product function and manufacturing process requirements.
0.06 (1.5mm) maximum, on all faces, features found in the locator core, on remainder of part.
6 Ejector Pin Bosses:

6.1 Boss Diameter:
6.1.1: In functional areas the size and location is dependent upon product function and
4A
manufacturing requirements.
6.1.2: In non-functional areas and on machined surfaces the ejector pin diameter is to
be 0.38 (10.0mm) minimum and the location is by mutual agreement of OEM and die
caster.
6.2 Surface Geometry:

6.2.1: 0.06 (1.5mm) raised to 0.03 (0.8mm) depressed.
7 Trimming & Cleaning:
7.1 Parting Lines:

7.1.1 Trim Ribs-Gate and Parting Line: 0.12 maximum (1.5mm)
7.1.2 Gates & Overflows: 0-0.059 (0-1.5mm)
7.1.3 Flash: As specified in normal standard.
7.2 Cored Holes: 0-0.02 (0-0.5mm)
7.3 Openings:
7.3.1: 0-0.06 (0-1.5mm) at the finish machined face
7.3.2: 0-0.03 (0-0.8mm) on as-cast surfaces
7.3.3: 0-0.01 (0-2.5mm) of corner radii
7.4 Corners - Sharp: Not removed.
7.5 Ejector Pin Flash (Max. Projection):
7.5.1: 0-0.12 (0-3.0mm) on machined surfaces.
7.5.2: 0-0.04 (0-1.0mm) on as-cast surfaces.
7.6 Machined Surfaces: 0.12 (0-0.3mm) max.
7.7 Seam Lines: 0-0.02 (0-0.5mm)
7.8 Negative trim (shearing): condition is allowed when the nominal wall thickness is maintained.
4A-43
4A-44

Section Contents
NADCA No.
Format
Page
4B-2
1 Introduction
2 Typical Design and Tolerance Data
section
4B
4B-2
S-4B-1-15
Standard
4B-3
3 Miniature Die Casting Machines
4B-4
4 Miniature Die Casting Dies
4B-4
5 Design Considerations for Miniature Die Castings
4B-7
5.1 Weight Reduction
4B-7
5.2 Ribs
4B-7
5.3 Shrinkage
4B-7
5.4 Draft
4B-7
5.5 Uniform Cross Section
4B-8
5.6 Fillets & Radii
4B-8
5.7 Surface Finish
4B-8
5.8 Parting Line & Ejector Pins
4B-8
5.9 Part Identification
4B-9
5.10 Side Cores
4B-9
5.11 Combining Functions
4B-9
5.12 Variations
4B-9
5.13 Skin
4B-10
5.14 Gears
4B-10
5.15 Threads
4B-10
5.16 Insert Die Casting
4B-10
5.17 Crimping, Staking, Bending and Forming
4B-10
6 Available Finishes
4B-11
7 Castable Zinc Alloys
4B-11
8 Glossary of Miniature Die Casting Technology
4B-12
4B
4B-1

1) W
hat is the difference between Section 4A and Section 4B, Miniature Die Casting?
See page 4B-2, Introduction.
2) W hat is a Miniature Die Cast Machine?
See page 4B-4, Miniature Die Cast Machines.
3) How tight can dimensional tolerances be held for mini-zinc castings?
See page 4B-3, Typical Design and Tolerance Data.
1 Introduction
Miniature die casting is a precision fabricating process similar to conventional hot chamber
die casting, but capable of much faster cycle times, tighter tolerances and minimal secondary
operations. It is often possible to combine multiple assembled components in a single cast piece
with significant total cost reduction. The process is capable of producing castings ranging in
weight from fractions of an ounce up to 16 ounces. Tolerances less than .001 of an inch with
virtually no part to part dimensional variation are routinely achieved. Miniature die casting
can yield flash-free, net-shape components of complex design from a variety of metals, specifically zinc, zinc-aluminum and magnesium. Zinc die cast components are often used as-cast
with no further treatment, however, various surface finishes can be applied to increase corrosion
resistance, provide aesthetic appeal, and/or improve mechanical properties.
Cycling up to 100 times per minute, automated, hot chamber, direct injection die casting
machines produce a component ready for tumble degating and subsequent shipment. Generally,
single cavity dies are preferred but when large volumes are required multiple cavity dies are used.
The single cavity principle insures that all parts are exactly alike. This can be a very important
consideration when automatic assembly equipment is used. High production rates from single
cavity tooling and the precision inherent in the machines, have combined to make this process
essential in numerous industries.
It is not uncommon for finished castings to cost as little as $.050 USD. Complete one time
tooling charges range from $7,000 to $75,000 depending on the complexity of the part and cavity
configuration. Miniature die casting has been successful for over 50 years and technological
advances continue to expand process capabilities with each year. Consult your miniature die caster
regarding your small component needs. There is probably a way he can save you time and money.
Figure 4B-1: 44NTX multiple slide die casting maching. Image courtesy of Techmire
4B-2
NADCA
S-4B-1-15
STANDARD
Typical Design and Tolerance Data
Because of their size and the specialized machines used, miniature die castings can be produced
to closer dimensional tolerances than larger castings. One of the advantages of miniature die
casting is that part to part variations are virtually nonexistent.
Tolerances on hole locations and other details that are influenced by shrinkage are obviously
easier to hold on small parts. Tooling is crucial to successful miniature die casting (see page 4B-4
Miniature Die Casting Dies) and when designed and built properly can produce castings that
are clean, flash-free and ready-to-use without secondary operations. This leaves the hard dense
surface of the casting undisturbed and thus increases wear resistance and strength.
Note:
standard and precision die
castings. However, in todays
six sigma world, capability
cast tools are often built to
and actual tool capability.
Six sigma variation and CPK
should be discussed with the
die caster in advance of tool
construction. Frequent repeatability (CP rather than CPK) is
the goal in the as-cast state. To
build a tool at nominal dimensions to get a good CPK will
lead to shorter tool life and
added rejects to the die caster
for process variations.
4B
Figure 4B-2 Examples of mini-zinc castings.
Note: Tolerances given below have been achieved and are strictly applied to multiple slide, miniature die
casting. The values may vary with size, design, and configuration of the component. Please consult your die
caster for establishing tolerances for specific part features.
Linear Dimension
+/-0.0008 up to 1 and
+/-0.020mm up to 25.4mm and
+/-0.001 for each additional inch +/-0.025 for each additional
25.4mm
The following values are typical for a 1.18 (30mm) component.

Flatness
0.002
0.05 mm
Circularity
0.001 (// to parting line)
0.03 mm (// to parting line)
Straightness
0.001
Angularity
0.001 in/in
Concentricity
Minimum Wall Thickness

Surface Finish (See paragraph 5.7)
Gears (See paragraph 5.14)
0.002 (// to parting line)

0.020
to 32 to 64 microinches
AGMA 6 - AGMA 8
Threads-External As-Cast (See paragraph 5.15) 2A
0.03 mm
0.001 mm/mm
0.05 mm (// to parting line)

0.50 mm
0.8-1.6 microns
6g
4B-3

3
Miniature Die Casting Machines
Miniature die casting machines may be small versions of traditional die casting machines or can be what
is referred to as multiple-slide machines (see Figure 4B-1). These machines are made by several different
manufacturers around the world. State of the art technology is available in these completely automated,
computer controlled machines. Some die casters custom build their own machines or modify commercial machines to better meet the needs of their customers. Miniature die casting machines commonly
use two to four slides. Five and even six slides have been used in very complex applications. The most
common multiple-slide machine is built to accommodate a two inch square die, but machines made
for four, six and eight inch square dies are also utilized.
With four sliding dies forming the details of a component, very intricate features are relatively
easy to cast to extremely tight tolerances that are nearly flash-free. Operating at approximately
2000 psi injection pressure, a two inch square, four slide machine, can cycle 100 times per minute.
Although average running speeds generally are in the 15-25 cycles per minute range. Pneumatic
and/or hydraulic cylinders are used to inject the molten metal into the cavity as well as move the
slides in and out. Some larger shots may require the use of hydraulic cylinders in order to accommodate necessary metal pressure and die lock up pressures. Smaller castings require less metal
pressure to fill properly and less time to solidify. Usually a blue print of the component is enough to
indicate what type of machine is needed to meet specified requirements.
Miniature Die Casting Dies
As with any form of die casting, miniature die cast tooling requires several basic considerations when designing a die to best meet your needs. Remember your die caster can make
this very easy for you since they have specific machine and process requirements that must be
addressed. The most obvious factors are: the shape or geometry of the part, the physical size of
the part, the part weight and the production requirements.
The shape or geometry of a part is probably the most important issue to be considered because the part
must be castable and still maintain its intended function. Usually a component(s) in an assembly can be
engineered to develop a practical part both castable and functional. If the parts intended function can
not be maintained, modifications mentioned after this section are extremely important when developing
a part. Your die caster will be able to advise on the most cost effective way to meet your needs.
The physical size of the part is one of the first factors considered in designing the die. There
must be an adequate amount of shut off steel outside the cavity that forms the part in order
to contain the metal during the injection phase. The amount of shut off steel necessary can
vary. A good rule of thumb is to maintain a minimum of 15% of the die head size per side (ex:
4 x 4 die head * 15% = 0.60 shut off per side). Therefore the part length and width should not
exceed 2.8 x 2.8 if intended for a standard 4 x 4 die (fig. 4B-3).
The part weight or volume of metal required will influence the type of die used. A heavier part may
effectively eliminate
the use of a pneumatic
machine and require a
hydraulically operated
machine. Generally, air
machines can consistently
produce good quality
zinc castings up to 2 oz.
Hydraulic machines are
used when exceeding
2 oz. Air is usually
preferred over hydraulics
because the machine can
cycle approximately 30%
faster. This allows for an
improved piece part price. Figure 4B-3 Example of a 4 x 4 die.
4B-4

SHANK #1
SHANK #3
CORE PIN
BLOCK HOLDER
RUNNER
SYSTEM
STATIONARY
EJECTOR PLATE
SHANK #4
DIE HEAD
CASTING
DIE HEAD
DIE HEAD
SEQUENCE:
OPEN: 2, 3, 4, 1
CLOSE: 1, 4, 3, 2
4B
SHANK #2
Figure 4B-4 Basic components of a miniature die casting die.
The production requirements will determine if miniature die casting is the right process to consider,
and if so, should multiple cavities be used. When high volume production is a must, multiple cavity
dies should be addressed. If casting tolerances are extremely tight, with stringent cosmetic callouts,
it may be necessary to limit cavity configurations in order to meet these requirements. Depending on
casting complexity, generally, fewer cavities means better attention to strict detail.
The basic components of a miniature die casting die are depicted in figure 4B-4. A die and a shank
comprise a slide. This illustration shows a four slide die using an ejector plate to strip the casting from
the die. The other method of ejection is to use standard ejector pins, which tend to leave marks on
the castings. Both are acceptable and
common practices. The decision on
which type to use must be addressed
during the design stages. The
machine is programmed to move the
slides in and out to a specific sequence. This illustration would have
the top slide (ejector) come in first
after the die is sprayed with lubricant
followed by the bottom slide, then
the left or right slides last. The metal
is then injected from beneath the
die using the hot chamber principle.
A typical gating system is shown
in figure 4B-5. After a very brief
solidification period, the slides cycle
out in the reverse sequence allowing
the ejector plate to strip the casting
free and be blown into a container
where it can be transported to a
degating operation.
Figure 4B-5 Typical gating system in a miniature die casting die.
4B-5

COMPONENT
MATERIAL
HARDNESS
Die
T-1
M-2
H-13
56-58 HRC
56-58 HRC
46-48 HRC
Inserts/Subinserts
H-13
46-48 HRC
Shank
S-7
54-56 HRC
Ejector Plate & Carrier
S-7
54-56 HRC
Ejector Pins
H-13
65-74 HRC Case Hardened
Core Pins
H-13
50-55 HRC Hardened Through
Crosshead/Frame
Gray Cast Iron
N/A
Construction materials and hardness requirements for typical miniature die components.
Figure 4B-6 Miniature die casting die shown without clamps.
Figure 4B-7 Miniature die casting die shown with clamps.
4B-6

5
Design Consideration for Miniature Die Castings
One of the factors that separate miniature die casting from conventional die casting is the use
of tools with fewer cavities. While production costs can be greatly reduced by the use of dies
with multiple cavities instead of a single cavity, it must be remembered that the cost of the die
increases with each cavity and that some loss of dimensional continuity will probably occur from
cavity to cavity. However, because they produce several parts for every casting cycle, multi-cavity
dies are practical for designs where quantities are very high.
Both the casting designer and the purchaser will benefit from a basic understanding of the
following design hints and by involving your die caster as early as possible. The experience that
he can share with you will help you design a better part at lower cost.
5.1
Weight Reduction
Reducing the volume of material needed

to produce a part will reduce material
cost. The more metal the part contains
the longer the time required to fill the
die cavity and cool the metal prior to
ejection, thus adversely affecting run
rates. Weight reduction can be achieved
by reducing the cross section or by
designing pockets. These thinner sections can be strengthened if needed with
ribs which can also improve metal flow. The size and location of weight
reduction pockets need to be carefully considered as they can sometimes
cause irregular shrinkage which may affect accuracy.
4B
5.2 Ribs
Ribs can be added to thin walled castings to increase part
strength. In addition, these ribs provide an ideal location
for ejector pins and assist in metal flow. Where possible,
ribs should be blended with fillets and radii to eliminate
sharp corners and rapid changes in cross section.
5.3 Shrinkage
Virtually all metals shrink as they cool to room
temperature. With the two most commonly used zinc
alloys, #3 and #5, this shrinkage is approximately .007
in. per inch. This shrinkage, which is always towards
the theoretical center, permits the casting to be released
from the outside walls of the cavity but tends to lock it
onto any die section that projects into it. This tendency
can be reduced by designing draft into the part.
1.0000
0.0350
0.0350
CAVITY
SIZE
CASTING
SIZE
AFTER
SHRINKAGE
5.4 Draft
Draft is the slight taper on the sides of cavity inserts which form any
internal features of a die casting. Draft is needed to make it easier for the
ejector pins to push the casting out of the cavity. Surfaces of the cavity
that have draft are usually highly polished for improved ejection. If no
draft is provided the die caster may be forced to use some of the dimensional tolerance for draft. However, minimal or no draft is required to
push or strip the casting out of the cavity when a stripper is used.
DRAFT
4B-7

5.5
Uniform Cross Section
CORNERS CAUSE TURBULENCE

AND RESTRICTED FLOW
By improving metal flow through the die,

uniform cross sections can speed up the casting
cycle. On the other hand, excessive changes in
cross section can cause turbulence in the die
cast metal. This tends to trap air which results
in porosity. A further consideration is that
castings with large differences in cross sections
tend to shrink irregularly.
5.6
UNIFORM
SECTION
Fillets & Radii
It is very important to avoid sharp corners,

especially when they are associated with a rapid
change in cross section. Whenever possible,
an inside corner should be designed with a
fillet an outside corner with a radius. This is
necessary to ensure good results when plating
operations are a requirement. Eliminating
sharp inside corners also gives added strength
to the casting and can improve fill by reducing
turbulence. Radii & fillets as small as .005 can
make noticeable improvements to a casting.
5.7
ROUNDED CORNERS
RADIUS
FILLET
Surface Finish
The surface finish of die castings are directly

related to the finish on the tool itself. As a
result, highly polished tooling can be expected
to give good surface finishes on the castings.
Miniature die cast parts are generally cast
with surface finishes between 32 and 64
microinches.
Of the many textured finishes that your die
caster can produce, a matte finish is usually
the easiest. Matte finishes are usually specified
to improve the appearance of a casting or to
highlight a logo or trademark.
5.8
Parting Lines & Ejector Pins
The plane where the two halves of the die meet,

is called the parting line. The outside shape
of the part determines where the parting line
must go. As a general rule the parting line
should be kept as flat or straight as possible. If
this cannot be done, changes from one level to
another should be as gradual as possible.
Castings are removed from the die by ejector
pins. Good toolmaking practices can reduce the
witness marks, but you will still be able to see
where they are located. A designer may specify
certain surfaces which must be free of parting
lines and ejector pins but you should give your
die caster as much leeway as possible.
4B-8
PL
E JE CT OR
P IN M AR KS
PL

5.9
Part Identification
The designer should consider what identification

marks are to be cast into the part and where they can
be permitted. All too often the die caster is asked
to add a part number or other identification to the
casting after the die has been built and sampled. This
can be very costly to do at this stage. Many die casters
like to identify their castings with their logo and the
cavity number in which the part was cast. Die casters
usually find it easier to produce raised letters as these
require less work in the die.
PL
PL
5.10 Side Cores

Side cores are required to produce holes or undercuts
that are parallel with the major parting line of the
die. As they add substantially to the tool cost, side
cores should be designed out wherever possible.
The line drawing showing one of the ways side
cores can be avoided.
5.11
Combining Functions
Probably the most effective way to reduce costs is to

combine several parts into one die casting. There are
many benefits from this, including reduced production
costs, as well as less handling, storage and assembly
costs. Often this results in a superior product as the design is less complex. The part illustrated was originally
produced in steel from two screw machined parts and a
stamping. Die casting eliminates the need to manufacture the parts separately, drill and tap the cross hole,
as well as pressing the parts together. The D shaped
hole eliminated the set screw and tightening operation
when the part was used in the final assembly.
SIDE CORE
REQUIRED
SIDE CORE
NOT REQUIRED
4B
SCREW
MACHINED
PIN
DIE CASTING
STAMPING
SCREW
MACHINED
BUSHING
SET
SCREW
BEFORE
AFTER
VARIATION
5.12 Variations
Savings can also be realized when there are a number
of different, but similar parts to be made. For
instance, an appliance manufacturer may use the same
electric motor to power several different appliances.
To accommodate this, several variations of bearing
brackets having slightly different configurations, may
be required. In these instances, a die can be designed
with multiple inserts so that one basic tool is capable
of producing the different variations. If variations
of the part being considered will be required in the
future you should give your die caster all the details
before he begins designing the tool. The line drawing
illustrates some of the different parts that could be
produced from one basic die which is designed with
replaceable inserts.
4B-9

5.13 Skin
One big advantage of as-cast parts is the
dense chilled skin on the outer surface which
has higher mechanical properties than the
rest of the casting. Designers should therefore
avoid machining this harder, denser material
especially on wear surfaces.
5.14 Gears
Miniature die casting can produce external,
internal, face, helical, spur and worm gears.
Virtually any tooth form can be cast, including
one with up to a 20 helix angle. AGMA 6-8
standards can be maintained depending on the
component configuration.
Shafts, ratchets and cams
can also be incorporated into gear components
through insert die casting.
5.15 Threads
External Threads
-Unlimited configurations
of external threads can
be miniature die cast
and can incorporate up
to 100 threads per inch.
However, to cast full
diameter threads (360)
very demanding toolmaking standards must be
maintained as the parting
line runs the full length of
the thread. Though possible and very impressive when done properly, full diameter threads are generally not necessary.
Wherever possible, flats to the root diameter of the thread should be allowed at the parting line.
This will reduce complexity in the die and thus lower initial tooling charges and piece part costs.
Internal Threads - Internal threads can be cast using a mechanism designed to rotate a core
in the die cast die. This adds cost to the die and the piece part. Generally internal threads are
tapped as a secondary operation for cost efficiency and speed. Form taps are typically used to
eliminate the process of removing cutting chips from the hole.
5.16 Insert Die Casting

Insert die casting can be used when design requirements necessitate the integration of components manufactured from other materials. There are systems available that load the components
into the cavity of the die cast die and the zinc component is then die cast around it. Insert die
casting can be a costly option and may require a dedicated die casting machine.
5.17 Crimping, Staking, Bending and Forming

Zinc alloys are capable of being crimped or staked, after die casting for assembly operations.
Secondary operations are dependent on wall thickness, alloy type, gate location and application temperature.
4B-10
4B
4B-11

6
Available Finishes
Chromates, platings, paints and powder coatings are the most common surface finishes. Chromates are conversion coatings applied through electro-chemical treatments to improve corrosion
resistance. These treatments convert the metal surface to a superficial layer containing a mixture
of chromium compounds of various colors and resistance.
Chromated components are corrosion tested in a 5% continuous salt spray environment as outlined
in ASTM standard B117. The following colors exhibit the varying performances; olive drab 96
hours of protection, bright yellow 48 hours of protection and clear 24 hours of protection.
Platings are applied to small zinc components for aesthetic purposes, and to improve corrosion
resistance, conductivity, hardness, wear resistance and solderability. The most common applied
platings are: Nickel, Brass, Tin, Copper, Silver and Gold.
Paints are used primarily for decoration, protection, identification, concealing surface irregularities or for increasing/decreasing surface friction.
Powder coatings provide a protective and attractive finish to components. They cover evenly,
have the ability to conceal surface imperfections, and provide good corrosion resistance.
For more information on finishes and coatings, see Section 6.
Castable Zinc Alloys
Zinc alloys are used in the production of small components because they are versatile, dependable, cost effective materials which can be used in an unlimited range of applications. As precisely formulated metal alloys, they offer the mechanical properties of medium strength metals.
The most commonly used zinc alloys in miniature die casting are #2, #3, #5, #7 and ZA-8.
These alloys offer higher tensile strengths than most aluminum and magnesium alloys, higher
yield strengths, greater impact resistance, higher Brinell hardness and better ductility.
Zinc alloys facilitate higher die casting cycle speeds versus aluminum and magnesium, more
complex shapes, thinner wall sections, smoother surface finishes, and higher standards of
dimensional accuracy.
Compared to plastic, zinc alloys are generally several times stronger and many times more rigid.
Their mechanical properties compare favorably with powdered iron, brass and screw-machined steel.
4B-12

Section Contents
NADCA No.
Format
Frequently Asked Questions
Page
5-2
1 Introduction
5-2
2 What is GD&T?
5-2
3 Why Should GD&T be Used?
5-2
4 Datum Reference Frame
5-4
4.1
Primary, Secondary, Tertiary Features & Datums
5-4
4.2
Datum Feature Vs. Datum Plane
5-5
4.3
Datum Plane Vs. Datum Axis
5-5
4.4
Datum Target Sizes & Locations
5-6
5 Feature Control Frame
5-6
6 Rule #1 Taylor Principle (Envelope Principle)
5-7
7 GD&T Symbols/Meanings
5-8
8 Material Conditions
5-8
8.1
Maximum Material Condition (MMC)
5-8
8.2
Least Material Condition (LMC)
5-9
8.3
Regardless of Feature Size (RFS)
5-10
9 Location Tolerances
5-11
9.1
Position Tolerance
5-11
9.2
Concentricity & Symmetry Tolerances
5-13
10 Profile Tolerance
5-14
11 Run Out Tolerances
5-18
12 Orientation Tolerances
5-19
13 Form Tolerances
5-21
13.1 Straightness
5-21
13.2 Flatness
5-23
13.3 Circulatity (Roundness)
5-23
13.4 Cylindricity
5-23
14 Conversion Charts
5-29
14.1 Conversion of Position (Cylindrical) Tolerance Zones

to/from Coordinate Tolerance Zones
5-29
14.2 Conversion of Position Tolerance Zone

to/from Coordinate Tolerance Zone
5-32
14.3 Conversion of Coordinate Measurements to

Position Location Measurements
5-33
section
5-1

1) Is
Geometric Dimensioning used on just Die Castings and why should it be used?
See page 5-2 - Why should GD&T be used?
2) W hat is a Location Tolerance?
See page 5-11, Location Tolerances
3) How do I convert a linear tolerance to true position?
See pages 5-32 through 5-34, Conversion of Position.
4) Is a list of GD&T symbols availible?
See page 5-8, GD&T Symbols and Meanings.
5) W
hen can I use Profile of a surface instead of flatness?
See page 5-14, Profile Tolerances.
1 Introduction
The concept of Geometric Dimensioning and Tolerancing (GD&T) was introduced by Stanley Parker
from Scotland in the late 1930s. However, it was not used to any degree until World War II (WW
II) because until then the vast majority of products were made in-house. The designer could discuss
with the manufacturing personnel (die designer, foundry foreman, machinist, and inspectors) what
features were to be contacted to establish the so called centerlines that were used on the drawing to
locate features such as holes and keyways. Also when two (2) or more features were shown coaxial or
symmetrical around these centerlines, the questions that needed to be answered by the designer was,
how concentric or symmetrical do these features have to be to each other?. During WW II companies
had to farm out parts because of the quantities/schedules. This meant the new manufacturer had to
interpret the drawing hence the centerlines were often established by contacting features that were not
functional or important and features produced from these incorrect centerlines were not at the location
required. The parts did not assemble and/or did not function properly and had to be fixed or scrapped.
GD&T was the solution to this major problem. GD&T provides a designer the tools to have clear,
concise, and consistent instructions as to what is required. It eliminates ambiguities so that everyone
involved with the part will not have to interpret the dimensioning.
What is GD&T?
It is compilation of symbols and rules that efficiently describe and control dimensioning &
tolerancing for all drawings (castings, machined components,etc.). It is documented in ASME
Y14.5M which has the symbols, rules, and simple examples. Also ASME Y14.8 has guidance
for casting and forging drawings.
Why should GD&T be used?
a. It is a simple and efficient method for describing the tolerancing mandated by the designer of the part.
b. It eliminates ambiguities as to what Datum features are to be contacted to establish the Datum planes
and/or Datum axis that are to be used for locating other features. All inspection will result in the same
result the dimension is within or out of tolerance. Fig. 5-1 illustrates a simple example of ambiguities
associated with the old type drawing. Fig. 5-2 illustrates the same example with GD&T.
c. It simplifies inspection because hard gages can often be utilized and inspection fixtures are
often mandated which simplifies inspection for production quantities.
d. It forces the designer to totally consider function, manufacturing process, and inspection methods. The
result is larger tolerances that guarantee function, but reduce manufacturing amd inspection costs. Also
the bonus or extra tolerance for certain conditions can result in significant production cost savings. In
addition the time to analyze whether a missed dimension is acceptable is dramatically reduced.
5-2
Figure 5-1 OLD Drawing without GD&T.
Questions:
1) What is the relationship (coaxiality tolerance) between the 1.00 and the 2.00?
2) Which feature (1.00 or 2.00) is to be used for measuring (locating) the .500.005 dimension for locating the .120 hole?
Figure 5-2 NEW Drawing with GD&T.
Questions asked in Fig. 5-1 answered:

1) The axis of the 2.00 has to be coaxial with the axis of the 1.00 within a tolerance zone that
is a .005 if the is 2.01 which is the Maximum Material Condition (MMC).
2) The 1.00 is the feature to be used for measuring the .500 dimension for locating the n.120
hole. The tolerance for locating the .120 hole is a of .014 (the diagonal of the rectangular
tolerance zone shown in Fig. 5-1) when the hole is a MMC (.120).
5-3

4
Datum Reference Frame (DRF)
The DRF is probably the most important concept of GD&T. In order to manufacture and/
or inspect a part to a drawing , the three (3) plane concept is necessary. Three (3) mutually
perpendicular (exactly 90 to each other) and perfect planes need to be created to measure from.
In GD&T this is called Datum Reference Frame whereas in mathematics it is the Cartesian
coordinate system invented by Rene Descartes in France (1596-1650). Often one would express
this concept as the need to establish the X,Y, and Z coordinates. The DRF is created by so-called
Datum Simulators which are the manufacturing, processing, and inspection equipment such
as surface plate, a collet, a three jaw chuck, a gage pin, etc. The DRF simulators provide the
origin of dimensional relationships. They contact the features (named Datum Features) which of
course are not perfect hence measurements from simulators (which are nearly perfect) provides
accurate values and they stabilize the part so that when the manufacturer inspects the part
and the customer inspects the part they both get the same answer. Also if the part is contacted
during the initial manufacturing setup in the same manner as when it is inspected, a layout for
assuring machining stock is not required. The final result (assuming the processing equipment is
suitable for the tolerancing specified) will be positive.
4.1 Primary, Secondary, and Tertiary Features & Datums

The primary is the first feature contacted (minimum contact at 3 points), the secondary feature is
the second feature contacted (minimum contact at 2 points), and the tertiary is the third feature
contacted (minimum contact at 1 point). Contacting the three (3) datum features simultaneously
establishes the three (3) mutually perpendicular datum planes or the datum reference frame. If the
part has a circular feature that is identified as the primary datum feature then as discussed later a
datum axis is obtained which allows two (2) mutually perpendicular planes to intersect the axis
which will be the primary and secondary datum planes. Another feature is needed (tertiary) to be
contacted in order orientate (fix the two planes that intersect the datum axis) and to establish the
datum reference frame. Datum features have to be specified in an order of precedence to properly
position a part on the Datum Reference Frame. The desired order of precedence is obtained by
entering the appropriate datum feature letter from left to right in the Feature Control Frame
(FCF) (see Section 5 for explanation for FCF). The first letter is the primary datum, the second
letter is the secondary datum, and the third letter is the tertiary datum. The letter identifies the
datum feature that is to be contacted however the letter in the FCF is the datum plane or axis
of the datum simulators. Note that there can be multiple datum sets used to reference different
features on the casting. See Fig. 5-3 for Datum Features & Planes.
Figure 5-3 Primary, secondary, tertiary features & datum planes.
5-4

4.2 Datum Feature vs Datum Plane
The datum features are the features (surfaces) on the part that will be contacted by the datum
simulators. The symbol is a capital letter (except I,O, and Q ) in a box such as A used in the
1994 ASME Y14.5 or -A- used on drawings made to the Y14.5 before 1994. The features are
selected for datums based on their relationship to toleranced features, i.e., function, however
they must be accessible, discernible, and of sufficient size to be useful. A datum plane is a datum
simulator such as a surface plate. See Fig. 5-4 for a Datum Feature vs a Datum Plane.
Figure 5-4 Datum feature vs. datum plane.
4.3 Datum Plane vs Datum Axis
A datum plane is the datum simulator such as a surface plate. A datum axis is also the axis of
a datum simulator such as a three (3) jaw chuck or an expandable collet (adjustable gage). It is
important to note that two (2) mutually perpendicular planes can intersect a datum axis however
there are an infinite number of planes that can intersect this axis (straight line). Only one (1) set
of mutually perpendicular planes have to be established in order to stabilize the part (everyone
has to get the same answer does the part meet the drawing requirements?) therefore a feature
that will orientate or clock or stabilize has to be contacted. The datum planes and datum axis
establish the datum reference frame and are where measurements are made from. See Fig. 5-5 for
Datum Feature vs Datum Axis.
Figure 5-5 Datum feature vs. datum axis.
5-5

4.4 Datum Target Sizes & Locations
Datum targets are datum simulators such as spherical pins or round flat bottom pins or three
(3) jaw chucks or centers that establish datum planes or a datum axis. They contact the datum
features and are often specified to be used for inspecting parts that are inherently not round or
straight or flat or they are large parts. If targets are not used then the entire datum feature has to
contact a datum simulator. An example of what can result is the part could rock on a surface
plate if the part was not relatively flat which would result in an unstable scenario and conflicting
results. If the datum feature is large a datum simulator that contacts the entire feature may not
exist or would be extremely expensive to produce. The datum targets are the datum planes and
datum axis and often are assembled together to create an inspection fixture and or a manufacturing fixture. See Fig. 5-6 for Datum Target Sizes & Locations.
Component configuration shown as phantom lines on separate drawing

Illustrates orientation when targets contact component
Illustrates that targets are physically separate from the component
Apply marking is shown to depict which side is to be contacted by the targets
Figure 5-6 Target sizes & locations.
Feature Control Frame
The geometric tolerance for an individual feature is specified in the Feature Control Frame which
is divided into compartments see Fig 5-7. The first compartment contains the type of geometric
characteristic such as true position, profile, orientation, etc. The second compartment contains
the tolerance (where applicable the tolerance is preceded by a diameter symbol and followed by
a material condition symbol). The remaining compartments contain the datum planes or axis in
the proper sequence (primary datum is the first letter).
Figure 5-7 Feature control frame.
5-6

6
Rule # 1 Taylor Principle (Envelope Principle)
When only a size tolerance is specified for an individual feature of size the form of this
feature shall not extend beyond a boundary (envelope) of perfect form at maximum material
condition (MMC). In other words, when the size is at MMC the feature has to be perfectly
straight. If the actual size is less than the MMC the variation in form allowed is equal to the
difference between the MMC and the actual size. The relationship between individual features
is not controlled by size limits. Features shown perpendicular, coaxial or symmetrical to each
other must be controlled for location or orientation otherwise the drawing is incomplete. In
other words Fig. 5-1 is an incomplete drawing. Fig. 5-8 shows the meaning of Rule #1 for an
external cylinder (pin or shaft) and an internal cylinder (hole). Note that a hard gage can be
used to inspect this principle or requirement.
Figure 5-8 Rule #1.
5-7

7
Tolerance
Type
Form
GD&T Symbols / Meanings

Applied To
Symbol Feature
Feature of
Geometric
Characteristics
Surface
Straightness
Circularity
Cylindricity
Positional Tolerance
Concentricity
Flatness
Location
Runout
YES
YES
NO
NO
Use L or M
Material Gages Used
Condition
YES
YES***
NO
NO
YES
YES***
NO
NO
NO
YES
YES
Symmetry
Parallelism
YES
YES
YES
YES
YES***
YES
NO
YES*
YES**
NO
YES
YES
YES
NO
NO
Orientation Perpendicularity
Profile
Size Dim.
Datum
Reference
Required
Angularity
Profile of a Line
Total Runout
Profile of a Surface
Circular Runout
* Can be used to control form without a datum reference.

** Datum reference only.
*** Yes if M is specified for the feature of size being controlled
No if S or L are specified for the feature of size being controlled.
Material Conditions
Features of size which includes datum features have size tolerances hence the size condition or
material (amount of metal) condition can vary from the maximum metal condition (MMC) to
the least metal condition (LMC). Consequently if the center planes or axes of a feature of size
are controlled by geometric tolerances a modifying symbol can be specified in the feature control
frame that applies the tolerance value at either the maximum or the least material condition. It
also can be specified for a datum that is a feature of size. If a symbol is not specified the tolerance
value applies regardless of material condition which is named regardless of feature size (RFS).
8.1 Maximum Material Condition (MMC)

This is the condition when the actual mating size or envelope size is at the maximum material
condition which is maximum size for an external feature such as a cylinder and the minimum
size for an internal feature such as a hole. Another way to look at MMC is that it always allows
components to be assembled. The symbol is M. The tolerance value specified for the feature being
controlled in the FCF applies only if the actual mating envelope is the MMC size. If the actual
mating envelope deviates from MMC an additional tolerance is allowed. The added tolerance is
the difference between the actual mating envelope size and the MMC size hence the largest actual
mating envelope named virtual condition is equal to the MMC size plus the tolerance specified
in the FCF for an external feature and minus for an internal feature. The MMC symbol is used
to assure that parts will assemble and it allows the use of so called hard gages (go gages) for quick
inspections. An example of position with MMC is shown in Fig. 5-9. It should be noted that
actual local size has to meet the size tolerance however the actual local size does not affect the
geometric characteristic tolerance.
5-8
5
Figure 5-9 Position control with MMC.
8.2 Least Material Condition (LMC)

This is the opposite of MMC consequently this is the condition when the actual minimum mating
size or envelope is at the minimum material condition which is minimum size for an external
feature such as a cylinder and the maximum size for an internal feature such as a hole. Another
way to look at LMC is that it always prevents components from being assembled. The symbol is
l. Additional tolerance is allowed if the actual minimum envelope deviates from LMC and is the
difference between the actual mating size and the LMC size hence the smallest actual mating size
is equal to the LMC size minus the tolerance specified in the FCF for an external feature and plus
for an internal feature. The LMC symbol is used to assure a minimum amount of machining stock
for features that are to be machined and for assuring a minimum amount of wall thickness between
external and internal features. Hard gages cannot be used for inspection. An example of position
with LMS is shown in Fig. 5-10. It should be noted that the actual local size has to meet the size
tolerance however the local size does not affect the geometric characteristic tolerance.
5-9
ACTUAL MINIMUM
MATING ENVELOPE
FEATURE BEING
CONTROLLED
TOLERANCE
ZONE
1.00
.005
1.01
.015
Figure 5-10 Position control with LHC.
8.3 Regardless Of Feature Size (RFS)

There is no symbol in the 1994 Y14.5 whereas it was s for the 1982 Y14.5. It is applicable if
the MMC or the LMC are not specified for individual features of size tolerances or for datum
features of size. The tolerance is limited to the specified value in the FCF and if applied to a
datum feature of size the actual axis or center plane have to be established regardless of the
feature size. It is always used for run out, concentricity, and symmetry controls as will be
discussed in those sections. It is also used when targets are specified to establish datum axes and
center planes because the targets have to contact the datum features to be useful. Also it is used
to control wall thickness variation between external and internal features. Hard gages are not
applicable since there is no additional or bonus tolerance as allowed for MMC and LMC. An
example of position with RFS is shown in Fig. 5-11.
5-10
ACTUAL MINIMUM
MATING ENVELOPE
FEATURE BEING
CONTROLLED
TOLERANCE
ZONE
1.00
.005
1.01
.005
Figure 5-11 Position control with RFS.
Location Tolerances
These include position, concentricity, and symmetry tolerances. Position is used to control
coaxiality of features, the center distance between features, and the location of features as a group.
Concentricity and symmetry are used to control the center distance of feature elements. These three
(3) tolerances are associated with datums because the obvious question is located from what?
9.1 Position Tolerance

Positional tolerances are probably used more than any other geometric control. It is used to locate
features of size from datum planes such as a hole or keyway and used to locate features coaxial
to a datum axis. The tolerance defines a zone that the axis or center plane of a feature of size may
vary from. The concept is there is an exact or true position that the feature would be if it was made
perfect however since nothing is made perfect a tolerance zone allows deviation from perfection.
The exact location of a feature of size is defined by basic dimensions which is shown in a box
() and are established from datum planes or axes. Coaxial controls are typically a cylindriNADCA Product Specification Standards for Die Castings / 2015
5-11

cal tolerance zone which has a diameter value and the true position is a datum axis. A positional
control is indicated by the position symbol (), a tolerance value (diameter symbol precedes the
tolerance value if desired), the applicable material condition modifier (m or l) if desired, and
the appropriate datum references placed in a feature control frame. When a material condition
modifier is specified a boundary named virtual condition is established. It is located at the true
position and it may not be violated by the surface or surfaces of the considered feature. Its size
is determined by adding or subtracting depending on whether the feature is an external or an
internal feature and whether the material condition specified is m or l. An example for controlling the location of holes is shown in Fig. 5-12 and of a keyway in Fig. 5-13.
Figure 5-12 Positional tolerancing of holes.
Figure 5-13 Positional tolerance for keyway.

Notes:
1) Datum B is the feature of size (5.000+.005) hence the true position for the keyway is the midplane of datum B.
2) No material condition modifier specified for either the keyway location tolerance .005 or the datum B, hence
the material condition is regardless of feature size for both features.
5-12

9.2 Concentricity & Symmetry Tolerances
These both control the median points of a feature of size: concentricity ( ) is applied to circular
features (often where the part or nearby parts are rotating) whereas symmetry (
) is applied to
non circular features. Both require that the median points of the controlled feature, regardless of
its size, to be within the tolerance zone (cylindrical zone for concentricity and two parallel planes
for symmetry). The tolerance zone is equally disposed about the datum axis for concentricity and
datum plane for symmetry. These controls are not used very often because median points are
difficult to establish due to irregularities of form and the only reason to use these controls is for
controlling the out of balance that can exist if the mass center is not close to the axis of rotation
or center plane. Examples of controlling concentricity and symmetry are shown in Fig. 5-14 &
5-15 respectively.
Figure 5-14 Concentricity tolerancing.
5-13
Figure 5-15 Symmetry tolerancing.
10 Profile Tolerances
Profile tolerances can control the location, orientation, and form of a feature that has no size (surface). There are two (2) types profile of a surface () and profile of a line (). The exact or true
profile of a feature is established by basic dimensions of radii, angular dimensions, and coordinate
dimensions established from datums however a profile tolerance can be specified to an individual
surface without specifying a datum see Fig. 16. The elements of a profile (outline of an object in a
given plane) are straight lines or arcs. The tolerance is a boundary of two (2) parallel planes disposed
(equally see Fig. 17 or in one direction see Fig. 16) and normal (perpendicular) along the perfect
or true profile within which the entire surface must lie. The profile can be controlled between two (2)
points see Fig 16. Also if datum planes are established by targets see Fig. 18 the tolerance zone
is equally disposed about the datum planes whereas if the datum planes are established by complete
contact with the datum features the tolerance zone is unidirectional and the tolerance value in the
FCF see Fig. 17 vs Fig. 18.
5-14
Figure 5-16 Profile control unidirectional and between points.
5-15
Notes:
1) All surfaces to be within .02.01 tolerance zone of true or perfect profile.
2) Datum A
B and C to be within .01 of datum planes A, B, and C.
Figure 5-17 Profile control all around entire part without targets.
5-16
Figure 5-18 Profile control all around entire part with targets.
5-17

11 Run Out Tolerances
Run out tolerances control the relationship of a feature relative to a datum axis established from one
(1) diameter or two (2) diameters separated axially see Fig. 5-19. The material condition applied to
the feature being controlled and the datum feature or features is always RFS because 360 rotation is
required to conduct the inspection. If targets are not specified to establish the datum axis the entire
datum feature has to be contacted which may not be practical. There are two (2) types of run out
controls circular () and total (). Circular run out controls the cumulative variation of circularity (roundness) and coaxiallity for features constructed around a datum axis and circular elements of
a surface constructed an angle not parallel to the datum axis (control wobble). The tolerance is the
full indicator movement (FIM) for each circular element independently as the part is rotated 360.
For each measurement the dial indicator is removed from the part after each 360 rotation and reset
at a new location. Total run out controls the entire surface simultaneously hence it controls cumulative variations in circularity, coaxiality, straightness, taper, angularity, and profile of a surface. The dial
indicator is not removed from the part after each 360 rotation. If applied to surfaces that are at an
angle to the datum axis it controls variation in angularity (wobble) and flatness (concavity or convexity). See Fig. 5-19 for circular run out and Fig. 5-20 for total run out.
Figure 5-19 Circular runout with targets.
5-18
5
Figure 5-20 total runout with targets.
12 Orientation Tolerances
There are three (3) separate orientation tolerances however two (2) of the three are specific values
of the general tolerance named angularity. The two (2) specific tolerances are named perpendicularity (90 to a datum) and parallelism (180 to a datum). These tolerances control the orientation
of features to a datum plane or axis. Angularity controls a surface (non feature of size), a center
plane or an axis of a feature of size to a specified angle and its symbol is . Perpendicularity
symbol is and parallelism symbol is and they do the same as angularity except the angles
are specific as previously stated. The tolerance zone may be either two (2) parallel planes at the
specified basic angle from a datum plane or axis within which the surface, center plane or axis
must lie or it may be a cylindrical zone within which the axis of the considered feature must lie.
Of course if angularity tolerance is specified for a feature of size the material condition modifiers
m or l may be specified. If neither m or l is specified then as always the regardless of feature
size (RFS) is applicable. See Figs 5-21 thru 5-23 for examples of , , and .
5-19
Figure 5-21 Angularity of a feature of size axis at MMC.
Figure 5-22 Perpendicularity of a feature of size axis at MMC with datum feature of size at MMC.
5-20
Figure 5-23 Parallelism surface.
13 Form Tolerances
There are four (4) form tolerances : straightness, flatness, circularity, and cylindricity. They apply
to individual features therefore the tolerances are not related to datums. Straightness can be used
to control the straightness of median line of a feature of size hence material condition modifiers
can be applied. The other form tolerances control surfaces hence material condition modifiers are
not applicable.
13.1 Straightness
There is one symbol () for straightness but there are two (2) kinds of controls that are very
different from each other. One control is for line elements of surfaces (FCF attached to the
surface) and the other is control of an axis or median plane of feature of sizes (FCF attached to
the size tolerance). The axis or median plane control relaxes the form control provided by Rule #1
because a perfect form boundary at MMC can be violated if the M symbol is specified. Fig. 5-24
illustrates control of line straightness and Figs 5-25 & 5-26 illustrate control of axis and median
plane straightness respectively. The surface straightness tolerance is only for line elements in the
view that the FCF is attached.
5-21
Figure 5-24 Straightness of a surface.
Figure 5-25 Straightness of an axis RFS.
5-22
Figure 5-26 Straightness of an axis at MMC.
13.2 Flatness
Flatness controls the distance between the high and low points of a surface. The tolerance zone
is the distance between two parallel planes that have no particular orientation. All elements of
the entire surface must lie between these two planes. See Fig. 5-27 for an illustration of flatness
control. The symbol is . Flatness is the same as straightness of a surface except straightness
controls line elements only in the view that the control is applied whereas flatness controls the
entire surface, i.e., all views.
13.3 Circularity (Roundness)

Circularity controls each circular element of a cylinder independent of each other. The circular elements of the surface in a plane perpendicular to an axis must lie between two concentric circles whose
radii differ by the tolerance value in the FCF. The symbol is . See Fig. 5-28 for an illustration.
13.4 Cylindricity
Cylindricity controls the entire surface of a cylinder. The tolerance zone is two (2) concentric
cylinders parallel to the axis of the actual mating envelope. The radii of the concentric cylinders
differ by the tolerance value specified in the FCF. It is a composite tolerance that controls
circularity, straightness, and taper. The symbol is . See Fig. 5-29 for an illustration.
5-23
Figure 5-27 Straightness of an axis at MMC.
Notes:
Each circular element in a plane perpendicular to an axis must be between two concentric circles with radii
that differ by .002. Also each element must be within the size limits.
Figure 5-28 Circularity.
5-24
Notes:
Cylindrical surface has to lie between two concentric cylinders with radii that differ by .01. Also the surface
must be within the specified size tolerance.
Figure 5-29 Cylindricity.
5-25
2.00
A2
-A-
A3
C1
1.50
-B-
A1
0.50
2.00
-C-
6.00
P/L
A. Top View
Center Line
Eject
B1
Eject
-C-
B. End View
B2
0.75
-A-
X
P/L
5.00
Core Slide
2.00
C. Side View
D. Isometric View
(All Target Areas on Same Side of P/L)
Figure 5-30 Example of an optimal datum reference framework for a die cast part design (all datums on same side of p/l).
5-26
2.00
P/L
-A-
A2
A3
C1
1.50
-B-
A1
2.00
0.50
Center Line
-C-
6.00
A. Top View
6.00
2.00
-C-
B. End View
Eject
-A3.00
P/L
X
Core Slide
X
B1
B2
C. Side View
D. Isometric View
(Target Areas A and C on Opposite Side of P/L From Target B)
Figure 5-31 Example of a less desirable datum reference framework for a die cast part design (datums across p/l).
May require additional qualification of some datums.
5-27
A2
2.00
-A-
A3
1.30
1.50
-B-
A1
2.00
C1
-C-
6.00
A. Top View
P/L
Center Line
Eject
6.00
2.00
-C-
B. End View
Eject
-A1.70
P/L
X
Core Slide
X
B1
B2
C. Side View
D. Isometric View
(Datum A is on Opposite Side of P/L from Datum B)
(Datum C is located on moving die component)
C1
Figure 5-32 Example of a least preferred datum reference framework for a die cast part design (datums across p/l
and datum on moving component). Will require qualification of all datums.
5-28

14 Conversion Charts
Coordinate dimensioning defines parts by their location on a three-dimensional grid, utilizing
the X-Y-Z coordinate system as in Fig. 5-2. Since the Coordinate Dimensioning System may
not consider part function when defining dimensions and tolerances, GD&T is a preferred
method of defining and dimensioning parts based on functional relationships to other parts and
part features. Sometimes it is necessary for dimensions and tolerances to be converted from one
system to the other. Geometric dimensioning and tolerancing is steadily replacing coordinate
dimensioning as more emphasis is placed on designing for manufacturing early in the product
design stage. This section will demonstrate how to convert between coordinate dimensioning and
geometric dimensioning.
14.1 Conversion of Position (Cylindrical) Tolerance Zones

to/from Coordinate Tolerance Zones
When converting total position (cylindrical) tolerance zones to total coordinate tolerance zones,
a general rule of thumb is that total coordinate zone is approximately 70% of total position
tolerance zone. This is only useful for non-critical applications. For example, for a non-critical
part to be converted from position (cylindrical) tolerance zone to coordinate tolerance zone, the
position (cylindrical) tolerance is multiplied by 0.7 (70%). The total coordinate tolerance zone is
then divided by 2 to obtain the bilateral tolerance zone.
Figure 5-33 visually demonstrates the conversion from coordinate tolerance zone to position
(cylindrical) tolerance zone.
5
.007 .007
Total TPositional
Tolerance
Zone
otal P os itional
T olerance
Diameter
Zone(C)
D iameter (C )
.0 025
45
.005 (B)
.0025
9 0
45
. 0025
. 0025
Total
Coordinate
or Bilateral
T otal
Coordinate
or B ilateral
Tolerance
Z
one
T olerance Zone
.0 05 (A)
Figure 5-33 Conversion of positional (cylindrical) tolerance zones to/from coordinate tolerance zones.
5-29
Figure 5-34 Conversions chart for converting between position tolerance and coordinate tolerance.
5-30
Total Coordinate Tolerance Zone =

[Total Position (Cylindrical) Tolerance Zone] X [0.7]
Example: Bilateral Tolerance Zone = [Total Coordinate Tolerance Zone] / 2
Sometimes parts require a more precise conversion. When a critical application is required, the
conversion factor is 0.70711. The position tolerance will be multiplied by 0.70711 (70.711%) to
obtain the total coordinate tolerance.
Total Coordinate Tol. Zone = [Total Position (Cylindrical) Tol. Zone] X [0.70711]
Bilateral Tolerance Zone = [Total Coordinate Tolerance Zone] / 2
For example, to convert 0.007 total position (cylindrical) tolerance to total coordinate tolerance:
Total Pos. Tol. Zone X Conversion Factor = Total Coordinate Tolerance Zone
0.007 Tol. X 0.70711 = 0.00495 ~ 0.005 Tot. Coordinate Tol.

Or
Total Coordinate Tol. Zone / 2 = Bilateral Tol. Zone 0.005 / 2 = 0.0025 Bilateral Tolerance
The following example demonstrates a simple conversion from total position tolerance zone to
total coordinate tolerance zone and bilateral tolerance zone. Figure 5-36 visually demonstrates
the conversion from position (cylindrical) tolerance zone to the coordinate tolerance zone.
When converting from total coordinate tolerance zone to total position (cylindrical) tolerance
zone, the total coordinate tolerance zone is multiplied by 1.4142. A bilateral tolerance zone is
multiplied by 2 then multiplied by 1.4142 to obtain the total position (cylindrical) tolerance zone.
For non-critical applications, it is acceptable to multiply the total coordinate tolerance zone
by 1.4 to obtain the total position tolerance zone. A bilateral tolerance may be multiplied by 2 to
obtain the total coordinate tolerance zone, then multiplied by 1.4 to get the total position tolerance
zone.
Total Position Tol. Zone =[Total Coordinate Tol. Zone] X [1.4142]

Total Position Tol. Zone = [Bilateral Tol. Zone] X [2] X [1.4142]
For example, to convert .005 total coordinate tolerance to total position (cylindrical) tolerance:
[Total Coordinate Tolerance Zone] X [Conversion Factor] = Total Position Tol. Zone
[0.005 Total Coordinate Tol. Zone] X [1.4142] = 0.007 Total Tol. Zone
Or
[Bilateral Tolerance Zone] X [2] X [Conversion Factor] = Total Position Tol. Zone
[0.0025 Bilateral Tol.] X [2] X [1.4142] = 0.007 Total Tol. Zone
5-31
14.2 Conversion of Position Tolerance Zone to/from Coordinate Tolerance Zone

Figure 5-34 is a chart for converting position tolerance zones to coordinate tolerance zones, and
for converting coordinate tolerance zones to position tolerance zones.
When looking at the conversion chart in Fig. 5-34, coordinate tolerance zones are listed across
the top of the grid and increasing from left to right, and on the right side of the grid increasing
from bottom to top. The position tolerances are listed on the left side of the grid and increase
from bottom to top. The position tolerances, however, follow the arced line across the grid. The
diameter of a position tolerance is given on the drawings, however, the diameter of a coordinate
tolerance is given by the length of the diagonal line. A diagonal line is drawn from the lower left
corner of the grid at a 45 angle to the upper right corner of the chart. The diameter is calculated
by using A 2 + B2 = C2. In figure 5-33, A is the total length of the horizontal line at the bottom
and connected to the circle, squared, plus B, the square of the vertical line at the left or right
edge and connected to the circle. Take the square root of the sum of the two sides will equal the
diameter C.
For example, suppose one wanted to convert a 0.010 diameter position tolerance to a coordinate tolerance. While looking at the chart in Fig. 5-34, begin at the 0.01 position tolerance on
the left side of the chart. Follow the corresponding arced line until it crosses the diagonal line
on the chart. Where the arced line and the diagonal line intersect, follow the horizontal line
across to the right side of the chart. The number on the right side of the chart that corresponds
with the horizontal line will give the appropriate bilateral coordinate tolerance. In this example,
the corresponding bilateral tolerance is 0.0035. To quickly verify this conversion, use the
multipliers identified in on page 5-31. Multiplying the coordinate tolerance by 0.7 will yield the
total coordinate tolerance. This number is then divided by 2 to obtain the bilateral coordinate
tolerance.
Position Tolerance = 0.010
Total Coordinate tolerance = Position Tol. X Conversion Factor = [0.010] X [0.7] = 0.007
Bilateral Tolerance Zone = Total Coordinate Tolerance / 2 = [0.007] / [ 2] = 0.0035
Bilateral Position Tol. = 0.0035

Total Position Tol = Bilateral Position Tol. X 2 = [0.0035] X [2] = 0.007
Position Tol. X Conv. Factor = [0.007] X [1.4] ~ 0.01
The number obtained from the conversion chart and the number obtained by using the multiplier
should be approximately the same.
Suppose it was desired to convert a coordinate tolerance such as 0.007 to a position tolerance. In order to use the conversion chart in Fig. 5-34, the coordinate tolerance must be in
bilateral coordinates, so 0.007 is divided by 2. This yields a bilateral coordinate tolerance of
0.0035. Next, the number .0035 is located on the left side of the conversion chart. Follow
the corresponding horizontal line across to the left until it intersects the diagonal line. At this
intersection, follow the intersecting arced line all the way across and to the left. The number
corresponding to that arced line on the left of the chart gives the associated position tolerance.
If done correctly, the position tolerance identified on the chart should be 0.010. This can be
double-checked by using the multipliers on page 5-31.
The number obtained from the conversion chart and the number obtained by using the
multiplier should be approximately the same.
To convert between position tolerancing and coordinate tolerance, either the conversion table
identified in Fig. 5-34, or the multiplication factor identified on page 5-31 may be used.
5-32
Conversion of Coordinate
Measurements to
Position Location
f Coordinate
ts to
tion
Figure 5-35 Conversions chart for converting between coordinate measurement and position measurement.
Figure 5-36 Schematic of conversion of coordinate measurements to position location.
14.3 Conversion of Coordinate Measurements to

Position Location Measurements
In addition to sometimes having to convert between position tolerance zones and coordinate
tolerance zones, it is also necessary to convert coordinate measurements to position location
measurements. When converting from coordinate measurements to position measurements, the
chart identified in Fig. 5-35 is used.
For example, if it was necessary to convert the position measurement 0.0311 to coordinate
measurements the following steps need to be accomplished. First, locate the number 0.0311
on the chart in Fig. 5-35. Once the number is located, follow the vertical column down to the
X-axis of the chart. The number identified at the very bottom of the column is the X-coordinate
measurement. In this example, the X-coordinate is 0.011. Now, relocate the number 0.0311
on the chart and follow the horizontal row to the right until it crosses the Y-axis. The number
on the very left end of that row is the Y-coordinate measurement. In this example, the
Y-coordinate is 0.011. Since position measurements are three-dimensional, a Z-coordinate must
5-33

also be identified. To find the corresponding Z-coordinate measurement, a simple equation
must be performed. This equation is as follows:
Z = 2
X2 + Y2
For this example, Z = 2 times the square root of X squared plus Y squared.
Z = 2
Z = 2
(0.011)2 + (0.011)2
(0.000121) + (0.000121)
Z = 2
Z = 2
Z=
0.000242
2(0.015556)
0.031112
The coordinate measurements that are associated with the 0.0311 position are
X = 0.011, Y = 0.011, and Z + 0.031112.
5-34
Engineering & Design:

Section Contents
NADCA No.
section
Format
Page
6-2
Introduction
6-2
1 Pressure Tightness
G-6-1-15
Guideline
6-3
2 Fillets
G-6-2-15
Guideline
6-4
3 Ribs and Corners
G-6-3-15
Guideline
6-5
4 Ejector Pins, Pin Marks and Pin Flash
G-6-4-15
Guideline
6-6
5 Metal Extension (Flash) Removal
G-6-5-15
Guideline
6-7
6 Surface Finish, As-Cast
G-6-6-15
Guideline
6-8
7 Die Cast Lettering and Ornamentation
G-6-7-15
Guideline
6-10
6-1

Pressure-tightness specifications for die castings,
to assure containment of
liquids or gases in use,
require deviations from
standard production and
inspection practice. Extra
steps, including special
pressure-testing equipment
and testing procedures, are
usually needed.

1) H
ow much flash can be expected to remain on a die casting after degating and trimming?
See page 6-7, Metal Extension (Flash) Removal.
2) If lettering is cast into the part, what are the options?
See page 6-10, Die Cast Lettering.
3) A re ejector pin marks required on the casting and will they have flash?
See page6-6, Ejector Pins, Pin Marks and Pin Flash.
4) W hat is a typical pressure tightness that die castings can withstand?
See page 6-3, Pressure Testing.
5) W
hat is the best surface condition I can expect on die cast surfaces?
See page 6-8, Typical As-Cast Surface Roughness Guide.
6) W hy add ribs to the casting in-place of thick sections?
See page 6-5, Ribs and Corners.
Introduction
The die casting specifications discussed in this section relate to aspects of die casting design
and production for which precise standards are difficult to set forth. As in previous Engineering
sections, they replace the former ADCI/NADCA E Series.
They include characteristics which are highly dependent on the design and shape of the
particular part to be die cast, such as pressure tightness of the finished part; the proper design
of fillets, ribs and corners in a part; the consideration of ejector pin locations, pin marks and
pin flash; casting flash and its removal; as-cast surface finish specifications; and the casting of
lettering, logos and ornamentation on the part surface.
While specifications will vary with the desired characteristic, certain guidelines have been established for die casting production under normal practice which can yield the most economic results.
It is obvious that close consultation with the die caster prior to freezing design decisions is the
wisest course to follow.
Pressure Tightness in Cast Parts
Assurance of pressure tight castings is highly dependent on the design configuration of the
part. Consultation with the caster in the early design stages is essential where a specification
for pressure tightness exists, in order to take advantage of basic product design, casting die
design, and production processing factors. All of these factors are involved in insuring pressure
tightness of the final cast part.
While most cast part designs can be cast pressure tight, specific castings may require impregnation to achieve required pressure tightness.
Special Notification Required

Specifications for pressure tightness will require deviations from standard production and inspection practice. Special pressure testing equipment and testing procedures are usually needed.
The requirement for pressure tightness should be made only where it is essential to the performance of the finished part. Where so specified, test methods and inspection procedures should
be agreed upon in advance between the customer and the caster. Duplicate test fixtures and test
methods are recommended wherever possible.
The discussion of Porosity and Pressure Tightness under Quality Assurance, Section 7 of
this manual, should be reviewed.
6-2

Guidelines for Pressure Tightness
Important considerations relating to the economical production of pressure-tight castings include
the following guidelines:
1. Product Design and Die Design

Successful casting of pressure-tight castings require close conformance to the principles of good
casting product design.
a. Guidelines concerning fillets, ribs and corners (G-6-2 and G-6-3), in this section, should be followed
very carefully.
NADCA
G-6-1-15
GUIDELINES
Pressure-tightness specifications for die castings,
to assure containment of
liquids or gases in use,
require deviations from
standard production and
inspection practice. Extra
steps, including special
pressure-testing equipment
and testing procedures, are
usually needed.
b. Part wall sections should be of uniform thickness as much as possible.

c. Holes and passages requiring pressure tightness should be cored to reduce porosity, as opposed to
machined after casting.
d. Ample draft should be provided in all cored holes and passages which are not to be machined. Cored
holes which are to be machined should be given minimum draft (see Draft Tolerances pg. 4A-21).
e. Heavy sections, as well as abrupt changes in sectional thickness, should be avoided.
f. Special vacuum casting techniques may be required in addition to special steps in temperature control,
the use of squeeze pins and other procedures to achieve final part specifications where the part design
does not conform to good casting design guidelines.
2. Secondary Machining
The nature of the casting process is such that the outer surface of a casting is usually dense. Thus,
thinner walls will be largely free of porosity, while thicker walls can be expected to contain some
porosity within. Pressure-tight designs must set strict limitations on secondary machining.
a. A minimum amount of machining stock should be removed, to avoid exposing porosity by cutting
deeply into a casting (see Machining Stock Allowance Tolerances, pg. 4A-40).
b. Large draft angles, which would require the removal of a large amount of stock from a surface to be
machined, should be avoided, particularly where holes are cored.
c. Machining both sides of the same section of a pressure-tight casting should be avoided.
d. Where machining can expose porosity, impregnation may be required to insure pressure tightness. (See
figure 7-5 in Section 7.)
3. Die Casting Alloy Selection

Certain alloys are best for producing pressure-tight castings. Refer to the Alloy Data sections
for alloy comparisons of pressure-tightness characteristics to aid in the selection of the most
favorable alloys.
4. Pressure Testing
Pressure-tightness testing for castings is generally specified in the range of 5 to 40 psi. Higher
pressures will require special consideration by the caster and will be almost entirely a function of
the part design.
In the case of pressure-tight casting requirements, review inspection procedures in of Commercial Practices, Section 8, and Porosity Control on pg. 2-11.
6-3

NADCA
G-6-2-15
GUIDELINES
These recommendations
regarding the design of
fillets, ribs and corners represent guidelines which will
result in die casting at the
most economic level under
normal production practice.
Sharp inside surface junctions, acute angle corner
conditions and delicate,
deep and closely spaced ribs
where and when necessary,
be involved.
Fillets in Die Cast Parts
Fillets
Intersecting surfaces forming junctions are best joined with fillets to avoid high stress concentrations in both the die castings and the die casting die. This will reduce die maintenance costs and
increase the life of the die.
In the sketches below, consideration has been given to the normal stresses on the die cast part
in use and to the stresses induced in the die castings by the casting process itself, as well as to
other manufacturing and die maintenance considerations.
Fillet Draft
Fillets projected in a direction normal (perpendicular) to the parting line require draft. The
amount of draft is always governed by the draft of the intersecting surface, if a constant fillet
radius is maintained.
Shallow vs. Deep Die Casting Designs

These suggestions apply to fillets on corners which are projected normal to the parting plane in
die castings of moderate depth. Shallow die castings may have much smaller fillets, while deep
pockets and other inside corners should have larger fillets.
Avoid Long, Sharp Corners

Long, sharply squared corners projecting in a direction normal to the parting plane may cause
spalled edges on the die casting and should be avoided.
Recommended Fillet Designs and Allowances
Less Desirable
WHERE T1 = THICKNESS OF THINNEST METAL AT JUNCTION

WHERE T1 = T2
ANGULAR TRANSITION
TEE JUNCTION
T1
T1
POINT OF
TANGENCY
Fig. 1
TEE JUNCTION
R1 = T1 TO 11/4 T1
WITHOUT
LIMIT
IF R 2 = 0; R1 = T1 TO 11/4 T1
T1 + T2
2
2(T1 + T2)
Fig. 3
T1
R1
Not Recommended
NO FILLET
Fig. 10
Fig. 11
WEAK CASTING, DIFFICULT TO MAINTAIN IN DIE.
R1
R2
T2
Fig. 6
T1
Fig. 4
2/
3
R1 = (T1 + T2)
R 2 = 0 TO R1 + R 2
R1
Fig. 7
Fig. 5
Q = 90; ALL RADII EQUAL T1
Q = 45; R1 = 0.7 T1 R 2 = 1.5 T1
Q = 30; R1 = 0.5 T1 R 2 = 2.5 T1
Fig. 9
DIFFICULT TO
MAINTAIN
IN DIE.
DEFLECTOR
R2
T1
T2
ANGULAR TRANSITION
INCREASES STRENGTH
BUT COSTLY DIE WORK.
CORSS OR Y JUNCTION
cross
Q
WHERE T2 > T1
R2
Fig. 8
HEAVY MASS HERE
NOT CONDUCIVE
TO SOUND METAL.
Fig. 2
IF R 2 = R1 + T1; R1 = T1
R1
R1
R1
T2
R1 Approaching
Zero
R1
T1
R1
R2
R1 Too Large
DEPRESSION PROMOTES
DENSITY, ESPECIALLY
UNDER CYLINDRICAL
BOSSES, BUT ADDS
TO DIE COST.
R1
Fig. 12
SHARP
IRREGULAR EDGE-DIFFICULT TRIMMING
NO FILLETS
Fig. 1
6-4
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

3
NADCA
G-6-3-15
GUIDELINES
Ribs and Corners in Die Cast Parts
Ribs
Ribs are used to increase the stiffness of, or add strength to, a die casting and to aid in making
sound die cast parts. Often, ribs add more strength to die castings than solid material due to
porosity. Ribs are sometimes misused and can be a detriment if working stresses are concentrated
by their use or if high stresses are created at the edges of the ribs by their design.
External Corners
Sharply squared external corners may be used in some locations if die construction permits. This
type of corner is mandatory at parting line locations and die block intersections. Elsewhere,
corners of die castings should have radii to prevent early die failure, to reduce the probability of
nicking the edge of the die casting in handling and assembly, and to minimize material handling
hazards for personnel.
These recommendations
regarding the design of
fillets, ribs and corners represent guidelines which will
result in die casting at the
most economic level under
normal production practice.
Sharp inside surface junctions, acute angle corner
conditions and delicate,
deep and closely spaced ribs
where and when necessary,
be involved.
Small Metal Savers

Ribs are often an integral part of making a die casting stronger, but a die cast part designer
needs to be cognizant of the steel as well. The empty space left in between ribs that serves no
functional purpose on the part is called a metal saver. Often, adding ribs close together can
result in thin or weak metal savers required in the die cast die to form the rib features in the
part. The designer should review the part for:
Relatively deep metal saver pockets
Relatively sharp edges to metal saver pockets
Relatively small draft on the sides of the metal saver pockets
All of the above should be avoided when designing the die cast part. The die caster or tool maker
can be consulted for design suggestions as well.
Recommended Rib Designs and Allowances
Not Recommended
R
h
h
T1
Fig. 1
T1
Fig. 2
h = T1
Fig. 3
WHERE h > T1 CORE OUT UNDERNEATH

TO AVOID UNDESIRABLE HEAVY MASS OF METAL.
BLENDING AS SHOWN
MAY BE DESIRABLE.
Fig.8
NO RIBBING BOSS
EXTENSIONS LESS
DESIRABLE FOR
CASTABILITY
BLEND
Fig.9
RIBS INSIDE GOOD DISTRIBUTION
OF METAL FOR ALL PURPOSES.
RIB
Fig. 4
Fig.10
Fig. 6
RIB FROM FLANGE TO BOSS

GENEROUS DRAFT AND FILLETS
NOTE ANGULAR TRANSITION.
GOOD DISTRIBUTION OF STRESSES
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
EXTERNAL RIBS MAY CAUSE

POOR DISTRIBUTION
OF STRESS
SHARP CORNERS
SMALL RADII
LITTLE DRAFT
Fig. 7
Fig. 5
Fig. 1
SHARP CORNERS
SMALL RADII.
BLEND
T1
Fig.11
Fig. 8
Fig. 9
Fig. 10
Fig. 11
6-5
NADCA
G-6-4-15
GUIDELINES
The guidelines presented
here for the location of
ejector pins, pin mark
tolerances and procedures
regarding pin flash represent standard die casting
most economic level. Disregarding these guidelines
should be done only when
and where essential to the
product design, since additional cost may be involved.

4
Ejector Pins, Pin Marks and Pin Flash
Ejector Pin Marks
Ejector Pin Operation
Moveable ejector pins must be used to eject a die casting

from the die casting die and will result in a residual ejector
pin mark on the die cast part.
In addition to automatically pushing the casting from
the die after part solidification, ejector pins also serve to
keep the casting from bending.
The sequential illustrations at right demonstrate the action
of the ejector pins in a die casting cycle.
Location Of Ejector Pins

Ejector pin locations should be at the option of the die
caster, subject to the customers agreement. Where considerations of cast surface cosmetics are important, ejector
pin locations should always be discussed in advance of die
design.
The number, size and location of ejector pins and bosses
required will vary with the size and complexity of the die
casting, as well as with other factors.
Figure A
Acceptable Ejector Pin Marks

Ejector pin marks on most die castings may be raised or
depressed .015 (.381 mm). Raised ejector pin marks are
preferred for optimum production. Larger castings may
require additional ejector pin tolerances for proper casting
ejection.
Figure B
Ejector Pin Operation

With each die casting cycle, the die opens and the ejector
plate in the ejector half of the die (Fig. A) automatically moves all ejector pins forward (Fig. B),
releasing the casting from the die. Then, the die casting is removed from the die manually or
mechanically.
Ejector Pin Flash

Ejector pin marks are surrounded by a flash of metal. Normally, ejector pin flash will not be
removed, unless it is objectionable to the end use of the part.
Alternatively, ejector pin flash may be specified as crushed or flattened.
In the case of either nonremoval or crushing/flattening, flash may flake off in use.
Complete removal of ejector pin marks and flash by machining or hand scraping operations
should be specified only when requirements justify the added expense.
Bumping Ejector Pins
Figure C
When ejector pins are placed on a flat surface, it can sometimes cause the side opposite the
ejector pinto bulge out on the part (called bumping). Bumping can be minimized by:
Increasing the wall thickness (increasing locally is an option as well).
Placing ejector pins neat veticle walls (distributes some ejection force to ribs).
Placing ejector pins on top of ribs.
Increasing draft.
6-6

5
NADCA
G-6-5-15
GUIDELINES
Metal Extension (Flash) Removal
Metal Extension (Flash) Formation and Location

An extension of metal is formed on die castings at the parting line of the two die halves and
where moving die components (also called moving die parts) operate (see Figure 6-1).
A seam of metal extension may also be formed where separate die parts cast a part feature.
Residual metal extension is also formed by the normal operation of ejector pins and is discussed
on the previous page.
The guidelines for removal

of die casting metal extension (flash) presented here
represent normal production practice at the most
economic level. Precision
flash trimming, closer
than standard commercial
trimming, or the complete
removal of all extension involves additional
operations and should
be specified only when
requirements justify the
additional cost.
Simplifying Extension (Flash) Removal

Necessary casting metal extension removal costs can be reduced by consideration, in the design
stages, of the amount of metal extension to be removed and the removal method to be employed.
Early consultation with the die caster can often result in production economies in the treatment of metal extension removal.
Guidelines to Extent of Removal

The table below provides a guide to the types of die casting metal extension (flash) which occurs
in typical die castings and the amount of metal extension material which remains after (1)
degating (removal of any gates and runners from the casting), and (2) commercial trimming of
die casting metal extension.
Note that in some instances, where special surface finish characteristics are not involved, the
most economic method of degating and metal extension (flash) removal may include a tumbling
or vibratory deburring operation.
Guide to Nominal Metal Remaining by Type of Extension
Type of Metal Extension and Nominal Amount Remaining After Degating and Trimming
Operation
Description
After Degating
Nominal Flash Remaining
After Commercial
Trimming*
Nominal Extension Remaining
Thick Gates &

Overflows
> 0.12 (3.0 mm)
Thin Gates &

Overflows
< 0.12 (3.0 mm)
Parting Line and

Seam Line Metal
Extension
Metal Extension
in Cored Holes
Sharp
Corners
Excess Only
Broken Off
Not
Removed
Not
Removed
Within
0.06 (1.59 mm)
Within
0.03 (0.8 mm)
Within
0.015 (0.38 mm)
Removed within
Not
0.010 (0.25 mm)** Removed
Rough within
0.12 (3.0 mm)
Rough within
0.12 (3.0 mm)
* Commercially trimmed does not include additional operations to remove loose material. For very heavy gates and overf lows, consult
your die caster.
** Shave trimming may be available to reduce amount of metal remaining in cored holes. Consult your die caster to determine what
options are available.
Figure 6-1: Examples of complex parting lines that can make flash extension removal more difficult.
6-7
NADCA
G-6-6-15
GUIDELINES
The as-cast external surface
finish classifications shown
here illustrate variations in
production practice. Surface
finish requirements should
be specified for production
at the most economic level.
Generally, extra steps in
die design, die construction
and casting production are
required for the more exacting finishes, and additional
cost may be involved.
Selection of the lowest
classification number, commensurate with the die cast
part application, will yield
the lowest cost.

6
Surface Finish, As-Cast
General Guidelines for As Cast Surface Finish on Die Cast Parts

The specification of external surface finish requirements is desirable for selected die casting
applications and, in the case of some decorative parts, essential.
The purpose of the guidelines presented here is to classify as-cast surface finish for die castings
into a series of grades so that the type of as-cast finish required may be addressed and defined in
advance of die design.
These guidelines should be used for general type classification only, with final surface finish
quality requirements specifically agreed upon between the die caster and the customer.
The first four classes listed relate to cosmetic surfaces. Class five relates to selected surface
areas where specified surface finish limitations are required.
As-Cast Surface Finish Classifications and Final Finish or End Use
Class
NOTE:
As-cast surface finish classification does not apply
to machined surfaces.
Finished machined surface
requirements shall be as
agreed upon between the
die caster and customer and
separately identified on the
engineering part drawing.
Utility
Grade
As-Cast Finish
Final Finish or End Use
No cosmetic requirements. Surface

imperfections (cold shut, rubs, surface
porosity, lubricant build-up, etc.) are
acceptable
Used as-cast or with protective coatings;

Anodize (non-decorative)
Chromate (yellow, clear)
Surface imperfections (cold shut, rubs,

surface porosity, etc.), that can be
removed by spot polishing or can be
covered by heavy paint, are acceptable.
Functional
Grade
Slight surface imperfections that can

Commercial be removed by agreed upon means are
acceptable.
Grade
Consumer
Grade
Superior
Grade
Decorative Coatings:
Lacquers
Enamels
Plating (Al)
Chemical Finish
Polished Finish
Structural Parts
(high stress areas)
Plating (Zn)
Electrostatic Painting
Transparent Paints
No objectionable surface imperfecSpecial Decorative Parts

tions. Where surface waviness (flatness),
noted by light reflection, is a reason for
rejection special agreement should be
reached with the die caster.
Surface finish, applicable to limited
areas of the casting and dependent on
alloy selected, to have a maximum value
in micro inches as specified on print.
O-Ring Seats or Gasket Areas
Typical As-Cast Surface Roughness Guide

Typical Surface Roughness (m-inches)
Alloy Family / Alloy
Expected in a New Die
Over the Life of a Die
Aluminum, ZA-12, ZA-27
63 or better
100-125
Zinc, ZA-8
32 or better
Magnesium
63 or better
63 should be maintainable
63 should be maintainable
Notes:
1. Part design, gate location, draft, flow lines, die surface treatments and other factors can impact surface roughness.
2. Roughness values for Over the Life of a Die do not include heat checking in the die.
3. Die lubricants utilized for special applications may impact surface roughness and the values in the table may not be achievable.
6-8

Legend for Advantages:
PRIMERS
PRETREATMENTS
Coatings for Castings

Coating
Applicable Material
Advantages
Price
A lodine 5200
A l, Mg
1, 2, 3
Low
Chromate (Class 1A & 3)
A l, Zn
1, 2, 3, 4
Low
I ron Phosphate
A l, Mg, Zn
1, 3
Low
N H 35
Mg
1, 2, 3
Low
Urethane
A l, Mg, Zn
1, 3, 5
Medium
Z inc Rich
A l, Mg, Zn
1, 2, 3, 6
E poxy
Z inc Chromate
Vinyl Acid Wash
OPERATIONS
POWDER
COATS
LIQUID
TOPCOATS
E -Coat
Urethane
E poxy
A crylic
Waterbase
F luropons/ Architect
Polyester
T GIC
Urethane
E poxy
ELECTROPLATING
ANODIC
FILMS
Hybrid
A l, Mg, Zn
Al
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
A l, Mg, Zn
1, 2, 3, 6
1, 2, 3, 5, 6
1, 2, 3, 5
1, 2, 3, 6
Low
Medium
3, 5
Medium
Medium
High
Medium
1, 2, 3
Medium
1, 2, 3
Medium
1, 2, 3, 5, 6, 7
H ardcoat - Hard Anodizing
A l, Mg
1, 2, 3, 6, 7
Medium
C opper
A l, Mg, Zn
1, 2, 4, 6, 8
High
Cu/Ni/Chrome
A l, Mg, Zn
1, 2, 4, 6, 8
High
Brass
Bronze
Z inc
S ilver
A l, Mg, Zn
A l, Zn
A l, Zn
A l, Zn
A l, Zn
A l, Zn
1, 2, 4, 6, 8
1, 2, 4, 6, 8
1, 2, 4, 6, 8
1, 2, 4, 6, 8
1, 2, 4, 6, 8
1, 2, 4, 6, 8
*A
nodizing of aluminum
is contingent upon the
specific alloy and may
not yield an aesthetically
pleasing surface.
Low
A l*, Mg
C opper/Nickel
7 UV resistance
Low
1, 2, 3, 5, 7
3 , 5, 7
5 Flexibility
8 Decorative finish
1, 3, 5, 6, 7
1, 2, 3, 5, 6, 7
4 Conductivity
Low
Medium
Medium
1, 2, 3, 5, 6, 7
3 Adhesion
enhancement
High
1, 3, 5, 6, 7
1, 2, 3, 6
2 Chemical
resistance
6 Hardness/
wear resistance/
durability/
mar resistance
Medium
A nodize
G old
ELECTROLESS
PLATING
A l, Mg, Zn
1 Corrosion
protection
Low
High
High
High
High
Very High
Very High
E lectroless Nickel
A l, Mg, Zn
1, 2, 3, 4, 6, 8
High
E lectroless Copper
A l, Mg, Zn
1, 2, 3, 4, 6, 8
High
For more details contact a viable coating source.

Note: Not all die castings readily accept electro-coatings. Vacuum plating f ilms such as PVD and CVD coatings,
mechanical plating such as Zinc/Tin, and thermal spray coatings may also be applied. Consult with the the
applicable coating suppliers.
6-9
NADCA
G-6-7-15
GUIDELINES
The guidelines presented
here for incorporating logotypes, lettering and ornamentation in a die cast part
represent normal production
practices at the most economic level. Fine detail in
lettering and art styles can
be achieved but may involve
additional costs.

7
Die Cast Lettering and Ornamentation
Lettering, medallions, logotypes, trademarks and a range of identification symbols may be

reproduced on the surfaces of die cast parts.
Such as-cast ornamentation may be raised or depressed, but note that raised lettering will
result in lower die construction costs and reduced die maintenance over the life of the die.
Raised lettering on a depressed panel can be an economical substitute for depressed letters, as
shown in the illustration below.
Cast-in Lettering/Ornamentation Guidelines

In addition to the avoidance of depressed lettering or symbols in the casting surface, the following guidelines will achieve the most satisfactory results. The terms used refer to the illustrations
below.
1. The Line Thickness (or face) of any letter to be clearly cast should be 0.010 in. (0.254 mm) or greater.
2. The Height (or raised dimension) of a cast letter or symbol should be equal to or less than the line thickness.
3. The Draft Angle should be greater than 10.
4. Letters or symbols containing fine serifs or delicate lines cannot be expected to die cast cleanly.
Sample Letter
or Symbol
Three Alternative Die Cast Effects

LINE (OR FACE)
SIZE
DRAFT
ANGLE
DRAFT
ANGLE
DRAFT
ANGLE
HEIGHT
6-10
HEIGHT
RAISED
DEPRESSED NOT
RECCOMENDED
RAISED IN
DEPRESSED PANEL
Fig. 1a
Fig. 2a
Fig. 2a
Fig. 1b
Fig. 2b
Fig. 2b
Quality Assurance
Section Contents
section
Page
7-2
Introduction
7-2
1 Balancing Process Capabilities with Product Requirements
7-2
1.1 The Engineering/Quality Team
7-2
1.2 Standard vs. Precision Tolerances
7-3
1.3 Simulation
7-3
2 Defining Product Quality
7-7
2.1 Internal Defects
7-7
2.2 External Defects
7-8
3 Drawings and Specifications
7-9
4 Gage, Measurement and Testing Equipment
7-10
5 First Article Inspection Requirements (FAIR)
7-10
6 Statistical Quality Control
7-11
6.1 SPC Procedures
7-11
6.2 Process Variables
7-11
6.3 Capability
7-12
6.4 PPM Levels
7-12
7 Porosity
7-12
7.1 Internal Porosity
7-14
7.2 Parting-Line Porosity
7-17
8 Pressure-Tight Castings
7-17
7-1
Quality Assurance
1) I s there information available about porosity in a die casting?
See pages 7-12 through 7-17 starting at Porosity.
2) W hat process variables affect the quality of die castings?
See page 7-11, Process Variables.
3) W here can information on die casting defects be found?
See page 7-7, Internal Defects.
4) W hen should CP or CPK be used?
See page 7-12, Capability.
5) I s a simulation really necessary?
See page 7-3, Simulation.
6) W hat are some typical images of porosity and/or breakout at parting lines?
See pages 7-12 through 7-17, Porosity.
7) C
an x-ray be used to view porosity?
See page 7-16.
Introduction
Continuing advances in die cast processing and control technologies allow the specifier of die
castings today to achieve very high levels of precision.
However, custom production requirements that are beyond readily manageable process
capabilities can increase costs. It is therefore essential that the user of die castings discuss process
capabilities with the die caster early to keep costs in line with expectations.
This section deals with the control of the variables in die casting production to achieve the specifications
presented in the earlier Engineering and Design Sections. It is the aim of this section to clarify terminology
and establish the criteria necessary to maintain acceptable product quality under normal die casting practice.
Communications by means of purchase orders, part drawings, CAD/CAM databases, corporate
standards, manufacturing specifications, die casting industry standards and guidelines should all
be used to clarify the job content. Working together to clearly define areas in doubt will obviously
result in optimum service at lowest costs.
Balancing Process Capabilities With Product Requirements
The best opportunity to reduce costs and enhance quality lies in carefully specifying those
characteristics that are clearly needed in the product, i.e., distinguishing between critical and
less critical features. When the functional requirements have been clearly defined, the die caster
can determine, in advance, the precise processing steps necessary to achieve them.
1.1
The Engineering/Quality Team
Developing the optimum set of product requirements consistent with process capabilities is best
accomplished by forming a cross-functional engineering and quality team involving all parties
who are concerned with the success of the product.
Often called a concurrent engineering or simultaneous engineering team, it should include
representatives of design engineering, manufacturing engineering (from both the die caster and
customer), quality assurance and marketing.1
If a formal cross-functional engineering team is not set up, an informal team of key personnel
from both the customer and the die caster should be formed to meet several times during the
product development process to address important questions.
7-2
Quality Assurance
1.2
Standard vs. Precision Tolerances
The die casting process can offer very high casting precision, as discussed under Standard and
Precision Tolerances in Engineering and Design, Section 4A. Precision Tolerance levels
should be specified only when product requirements justify the additional production steps that
may be required. Otherwise industry Standard Tolerances should be used.
It is always advantageous, in terms of faster delivery and lower production costs, to avoid
unnecessarily stringent tolerances and specifications.
1.3 Simulation
The term Lean is used to describe a manufacturing process. Lean is continually striving for
perfection, continually declining costs, zero defects, zero inventories, and an increase in business.
There are five major principles used in Lean Thinking!
Value: Only the ultimate customer can determine value!
Value Stream: All the actions and services required to bring a specific casting to market.
Flow: Flow is a continuum from the order desk to the shipping dock. No stopping or storing!

P ull: The customer can pull the product from the caster because of the quick turnaround
time. Pulling is like turning on a switch for the desired product.
Perfection: There is no end to the process of reducing effort, time, space, cost, and mistakes.
Lean employs five principles, but we will use two of those principles to highlight our improvement for Product Integrity. Value Stream is one of those concepts: All the actions and services
required to bring a specific casting or family of castings to market in a logical, timely sequence
that promotes perfection. Perfection is an overriding principle for our premise of improvement:
Make sure we know exactly what the customer wants.
Recent software tools such as CAD/CAM, shot monitors, and simulation programs all assist
the industry in achieving perfection. Often times these tools are not used at all or are used
out of the proper sequence for achieving perfection. As technology in software improves, the
industry must use the advantages offered for a profitable timesaving. When NADCA metal flow
principles are properly employed it increases the probability for sample castings to be approved.
When a shot monitor is employed the engineering department can easily determine machine
capabilities and create a realistic PQ2 analysis. When vacuum metal flow simulation software
is used the runners, gating, vents, overflows and vacuum vents can all be properly placed for
minimal defect metal flow. It may take several simulation iterations to ensure the runners and
gate placement creates the desired metal flow pattern.
There are many automated features on the die cast machine, trim dies, and subsequent
machining operations. If the mold is not producing an acceptable casting the speed created is not
in the Perfection Mode of Lean Thinking.
For example, the following steps are used for a typical metal flow simulation:
Engineering will create a 3-D model of the casting with runners and gates connected and export
the file in an STL format for the simulation. A PQ2 analysis will yield the desired fill time and
optimum gate area. The gate depth and location can be determined for the simulation.
A fast simulation, in the initial design stage can be made to ensure the position of inlets
will yield the desired perfection. This is a critical stage to ensure the holder and mold will
be oriented for machining. The neglect of this sequence in the value stream may result in
welding and refashioning runners & gates, resulting in a time and material loss. If the gates
have to be moved the result may result in a shortage of tool steel for the new gates. Emphasis
must be placed on the proper sequence to avoid mistakes, rework and ultimate delays in the
delivery of the mold. Perfection is a must at this step in the value stream.
7-3
Quality Assurance
Critical questions to ask at this critical stage are:
Does the inlet gate satisfy the feeding of each cavity?
Is the last place to fill well defined? (Figure 7-1)
Are the overflows and/or vacuum lines in the last place to fill?
Are there areas that may be porous or not filling properly? (Figure 7-2)
Does it seem the gates are placed correctly? (Figure 7-3)
Has a PQ2 analysis determined gate size and filling speed? (Figure 7-4)
Has the casting been checked for square corners or areas of difficult fill? (Figures 7-5a & 7-5b)
Will major changes have to be made to ensure perfection?
If the simulation determines a change, the recommendations are put into a new model and
STL for another iteration. If it seems the gate is adequate or a slight change is needed the
mold can be aggressively machined. A fine, more accurate simulation can verify all the data.
Figure 7-2: This simulation shows the end

and top overflows are of no value. The cavity
areas encircled are filled with porosity. The
scrap rate was 75%. A new gate/runner
with confirming simulations yielded a 1.5%
scrap rate. The simulation will save hours of
rework and lost time.
Figure 7-3: The metal flow in the outer runners is well past the two inner runner/gates.
Gate placement must ensure the maximum
use of available gate area. The angle of metal
entry must be within metal flow capabilities per NADCA standards. Seeing the flow
enhances the needed changes for proper fill.
Figure 7-1: This is an example of the overflows filling

first instead of being the last
place to fill. An initial fast
simulation will detect such
undesirable characteristics.
Figure 7-4: This simulation is depicting a velocity that is too slow, the metal
flow is freezing before the final fill.
A PQ2 analysis will render a proper
gate and metal flow velocity to ensure
a complete fill. Simulations show very
accurately the filling characteristics.
7-4
Figure 7-5b: A zinc cosmetic casting

that has square corner metal flow that
results in unacceptable porosity. A visual
defect!
Figure 7-5a: Square corners
in a runner or casting result
in porosity. pockets.
Quality Assurance
Figure 7-6: Simulations of liquid fraction (left) and feeding velocity (right)
at porosity initiation and ingate cutoff for a ribbed casting configuration.
Figure 7-7: Thermal simulation showing the temperature gradient at a given

point in time of castings in a 4-cavity die.
Figure 7-9: An example of distortion modeling, 20x magnification factor.
Figure 7-8: The selected part for

simulation.
Figure 7-10: An example of residual stress prediction at time of ejection using elasticplastic analysis.
Simulations can be used to optimize heat flow, determine the location of cooling lines and cooling
requirements. Simulations can also be used to predict die distortion, casting ejection temperatures and
dimensional capability, last place to fill, and areas of poor fill or non-fill, and pockets of porosity. They
also indicate where the overflows should be placed as indicated by the last area of the casting to fill.
A time and cost saving for the entire supply chain is to have accurate information for the mold-maker
to complete the mold building. Time and price increase when the project is delayed because of minute
changes or uncertainty of design. The customer, caster, and mold maker must all be informed of the
part design and specific areas of special concern. All questions must be answered so every party can be
aggressive in executing their expertise. Then the project can mature in an orderly and speedy fashion.
FAQ Concerning Simulation:
What is the value or benefit of a simulation?
The simulation will give an accurate, graphic depiction of the filling process and will verify the suggested
gating profile. Many times a runner and gate are cut only to find the results are not in the perfection
mode of desirability. The simulation must be done prior to cutting steel.
7-5
Quality Assurance
Are the simulation results easy to understand or read?
It requires a skilled engineer or experienced person to explain the results. Any computer literate individual can create the simulation, but experience is required to understand the results.
Is the simulation cost effective?
If a caster or mold maker owns the software it can and should be used on virtually every project. There
are also consultants who will be cost effective in conducting a simulation. The process saves countless hours
of die changes, welding and machining of gates to enhance flow. The relative small cost of the simulation
saves time, money and increases the availability for increased business. The true reward for a proper value
stream sequence is realized when the project goes into production as a result of careful planning and timely
execution. All the members of the value stream make a profit and have capacity for increased business.
Finite Element and Finite Difference Methods

Both finite element and finite difference methods are used to numerically solve the partial differential
equations that describe physical phenomena including heat transfer, fluid flow, stress, displacement,
distortion and others. Both techniques require discretizing the object or spatial domain of analysis into
a grid of nodes and applying numerical techniques to solve the problem of interest at these nodes. The
main differences in the methods arise from differences in the solution techniques used.
Finite difference uses a grid of points, almost always uniform, and the derivatives present in the
differential equations are approximated by differences constructed using neighboring points, hence the
name. The problem is thereby reduced to a set of simultaneous equations that are solved iteratively.
Because the grid is uniform, finite difference grids may not perfectly follow the surface of the
object and may have a stair step like appearance. Newer grid generation procedures minimize these
effects but not all finite difference-based programs support them.
Finite element also discretizes the space into a grid, but it is not necessarily uniform. Instead the
spatial domain of the analysis is decomposed into discrete elements. The elements generally are
polyhedra either with 6 rectangular sides and 8 corner nodes (brick elements) or four triangular sides
and 4 corner nodes (tetrahedral elements). Accurate tetrahedral meshes are easily created by automatic
meshing programs. Because of the meshing procedure FE meshes provide excellent surface fidelity.
Finite element methods solve the differential equations by using an approximate solution defined
within the element in terms of the solution value at the nodes. Neighboring elements share nodes and
the solution much match at these nodes leading to a set of simultaneous equations that must be solved
consistent with specified boundary condition. Each element has so called fitting functions that are used
to interpolate the solution within the elements and, because the element contains the approximate solution, different element types are required for each type of problem to be solved. That is, even with the
same geometry and mesh, different elements are used for heat transfer and stress analysis for example.
Finite elements will always have nodes at the corners and may have nodes at the center of each edge and
at the center of the element depending on the element type and the solution approximation technique
that is used. Even with the extra nodes, finite element meshes generally contain a smaller number of
nodes than a finite difference grid for the same problem.
In principle either technique can be used to solve the differential equations of any of the
common engineering problems although finite difference tends to the method of choice for fluid
dynamics problems (such as metal flow analysis) and finite element for stress and deflection. Both
methods handle heat flow equally well. For either type of system, there can be wide differences
in the implementation of a particular type of solution across vendors. Also, for both special and
general purpose packages, not all will have the ability to address nonlinearities such as contact
and movement between components of the system (e.g., contact between the die and the machine
platen or contact between the casting and cavity wall). The quality of the solution depends more on
the quality of the implementation than on the method.
7-6
Quality Assurance
Figure 7-11 A: 2D illustration of the difference between finite difference and finite element meshes.
Defining Product Quality
The definition of product quality is fitness for end use. The definition will vary from
design to design and usually varies for different areas of the same part.
The designer should expect to commit sufficient time and resources with the custom die
caster, in the preliminary design stages before final drawings are completed, to determine
what constitutes casting defects, and to precisely define acceptable product quality. This
critical step will reduce rejections and rework, promote smooth operations between the
die caster and the customers design and procurement staff and increase successful results.
The checklists C-8-1 and C-8-2, which appear at the end of Commercial Practices,
Section 8, should be used in specifying quality requirements.
It is rarely, if ever, practical to eliminate all casting discontinuities. Any attempt at total
elimination will usually increase the cost of the casting unnecessarily.
There are two general types of discontinuities: internal and external. Internal defects
can affect the structure of the casting, and may or may not be visible on the surface.
Figure 7-12: Magnified view of a non-metallic inclusion as an

example of an internal defect other than porosity.
2.1
Internal Defects
Porosity is the most common type of internal defect (see page 7-14 Internal Porosity). In many
cases internal porosity will have little or no effect on the overall strength and integrity of a casting.
Where pressure tightness for a gas or liquid application is not a requirement, a mechanical
strength test (by a standard weight drop or torque wrench application) per an agreed upon
sampling plan can be a cost-effective approach to quality assurance for casting strength.
7-7
Quality Assurance
Figure 7-13: Cp is the raw capability index or in simpler

terms = repeatability.
Figure 7-14: Cpk is the Total Process Capability or =

accuracy and repeatability.
Normal Distribution
0.5
99.95
0.4
99.73
0.3
98.76
0.2
0.1
0
Figure 7-15: Cp can be applied to a bimodal distribution

that allows for migration from one side of the tolerance
range to the other. The higher the Cp number the more
repeatable the process is.
2.2
-6 -5 -4
-3
-2
-1
Figure 7-16: CPK indicates a normal distribution that

allows within the distribution the maximum allowance of
plus/minus tolerance that yields the greatest number of good
parts in production. The higher the CPK number the more
repeatable and accurate the process is.
External Defects
External, or surface defects, do not generally affect the structure of the casting. Surface defects are
especially sensitive to the particular design of gates and runners in the die casting die. Calculated
design parameters using proven metal flow design and process simulation techniques have been
shown to be very effective.
The type and severity of external defect that can be accepted depends greatly on the type
of final surface treatment to be applied. For example, a powder coating application deposits a
relatively thick coat compared with painting systems, and will tolerate greater levels of surface
roughness. Bright plating, such as chrome or brass, requires a very smooth surface finish.
Surface finish standards for die castings are normally developed on a part-by-part basis between
the producer and the user.
It is important that the final finish acceptance standards developed be understood and agreed
upon by all parties, with reference to a specific viewing standard such as no objectionable
imperfections, as specified, when viewed under normal lighting conditions at XX feet viewing
distance. This can be addressed on checklist C-8-2, in Section 8, checklist item Q.
Reference sample standards should be retained by all parties after agreement on the acceptable standard.
Some common types of surface defects that may occur in production over time are cold shuts
(knit lines), swirls (surface roughness), build-up (die lube or soldering accumulation) and heat
checking (very small raised fins on parts). See Guideline G-6-6 Surface Finish, As-Cast on
page 6-8 for more details.
7-8
Quality Assurance
Figure 7-17: Examples of external defects.
Heat checking occurs during the life of a die when small cracks appear in the die due to thermal
cycling. They sometimes cause concern on structural features because they appear, to the untrained
eye, as cracks on a part. However, they do not affect the structural integrity of the casting, and are
not generally objectionable on structural features that do not have cosmetic requirements.
Raised fins are routinely removed by surface blasting with shot or grit, or by vibratory finishing
(which is normally the procedure used to prepare the surface for painting). How external defects
are to be removed or eliminated depends on the type of surface finish required, whether painted,
plated, or functional. The method to be used should always be discussed with the die caster. For
more information on die casting defects see NADCA publication #E-515 Die Casting Defects
Causes and Solutions.
Drawings and Specifications
To insure uninterrupted production to specifications at the most economical level, it is important to

supply all drawings and specifications to the die caster with the Request for Quotation (RFQ ).
For correlation purposes, it is necessary that the drawings and specifications contain the
following information:
01. Dimensions or areas that are of critical, major or minor importance, and the Acceptance Quality Level
(AQL) or Parts-Per-Million (PPM) level to which they will be checked, including the dimensions for
which the customer will be requesting control charts.
02. Datum locations to be used for machining or gaging and the areas to be used for special checking
03. The gaging procedures the customer intends to follow and the special gages that will be furnished.
04. Special requirements and the areas to which they pertain.
05. Coded surfaces on parts to be plated, painted, etc., designating classification of surfaces.
06. Indication as to where die trimmed edges are not acceptable and specification of degree of metal extension removal required (See Metal Extension, G-6-5, in Section 6).
07. Indication of any engineering change level requirements by purchase orders and accompanying drawings.
08. Specification of those surfaces which may not be used for location of the ejector pins.
09. A list of generic print tolerances which will adequately describe all the non-critical areas on the print.
10. Clear description of all standards for approval or rejection.
Providing detailed and complete specifications at the time of the RFQ will benefit both the customer
and the supplier. It will enable the die caster to submit more accurate, competitive quotes and help assure
that the customer will receive quality die castings at the most economical level.
7-9
Quality Assurance
4
Gage, Measurement and Testing Equipment
Proper gaging equipment must be provided for effective measurement of product conformance.
The customer is expected to furnish special-purpose gages which are required for inspection of
specific die castings.
Special gaging requirements should be stated and the responsibility for maintenance of special gages
should be established on the RFQ and on subsequent contracts between the die caster and customer.
Gaging labor, when applicable, is included in the price quoted for the die casting.
When special gaging fixtures are necessary, they should be made in duplicate by the customer
and one set furnished to the die caster. The customer should also furnish complete inspection
methods and gage design information to the die caster at the time of the request for quotation. A
gage and measurement instrument calibration system, with records maintained by the die caster,
will assure consistent measurement control.
It is also suggested that gage Reproducibility and Repeatability (R & R) studies be done on all
customer-supplied special gages. Further, it is recommended that all gaging sets be qualified by
both the customer and die caster.
The responsibility for any preventative maintenance to be performed on customer-owned gaging
should be made clear.
First Article Inspection Requirements (FAIR)
Whether the die caster or the customer is to perform the inspection of initial samples produced
from a die casting die should be decided at the time the purchase order is issued.
When the inspection of initial samples is completed by the die caster, a report of the findings
will be submitted to the customer. This is frequently referred to as a First Article Inspection Report
(FAIR). Unless otherwise specified, first piece samples are supplied for dimensional check only.
(Inspection of initial samples by the die caster may result in added cost.)
At the customers request, the die caster will be responsible, after the inspection of initial samples, for
correction of tooling for out-of-specification part dimensions before the start of production.
The customer should change the print for those dimensions for which tooling correction is not
required in order to agree with the initial samples report. The general print tolerance will apply to
the changed dimensions as noted, unless there is agreement to a new tolerance. Any automotive or
other industry requirements such as preproduction approval pieces (PPAP) should also be known at
the time of quoting. See figure 7-22 on an example PPAP flow chart.
In the event a print change will not be made, the customer should furnish an inspection report
specifying those dimensions or tooling corrections which are not required. Any dimension not
requested to be corrected or changed on the print is considered a valid dimension with normal
tolerances, after the start of production, for the life of the tool.
The customer must acknowledge part acceptance by a formal letter before production is run.
Such acknowledgment indicates either conformance to print or acceptance of a permanent
deviation from specifications. The general print tolerances will apply to any deviations. Any die
castings received by the customer which conform to the approved sample dimensions will be
considered acceptable product.
If capability studies are to be done at the time of first-piece inspection, or in place of first piece
inspection, this requirement should be specified at the time of the RFQ. Any automotive or other
industry requirement such as Pre-Production Approval Process (PPAP) should be known at the time of
quoting.
7-10
Quality Assurance
6
To assure uniform quality control standards acceptable sampling procedures and tables for
inspection by attributes, such as ANSI/ASQC Z1.4, should be used.
Characteristics to be inspected for product conformity should be agreed upon by the customer
and supplier prior to the first production run.
The classification of particular characteristics and AQL or PPM levels should be determined at
the time the contract is negotiated. Classification of defects (critical, major, minor) should be in
accordance with the latest revision of the acceptable sampling procedures to be utilized.
Normal inspection, as per ANSI/ASQC Z1.4 for instance, should be used.
Sampling plans to be used by the die caster will be left to the discretion of the individual die
caster, recognizing, however, the responsibility to meet the agreed upon AQL or PPM levels.
6.1
SPC Procedures
Where the current revision of ANSI/ASQC Z1.4 is not desired or appropriate, a negotiated
standard of sampling and acceptance should be established prior to die design, with early determination of SPC recording. Any requirement for process potential data or process capability studies
should also be outlined at that time.
Dimensions and/or parameters requiring SPC data and Cp and Cpk values should be agreed
upon by the customer and die caster prior to the first production run. This should include types of
SPC charts, subgroup size, and sampling frequencies.
Determination must be made prior to production as to all specific SPC reporting requirements,
data maintenance and its transmission. The die caster should be expected to point out to the
customer the impact on Cpk values when cast die features are built on the steel safe or wear safe
side of nominal, to allow the tooling maximum tool life and wear towards nominal dimensions.
6.2
Process Variables
There are five process variables that affect the quality of the die casting:
1. Metal analysis
2. Metal temperature
3. Die temperature
4. Die lubricant characteristics
5. Die filling conditions
In general, die casting is a setup-dominant process that exhibits variation of a serial, rather
than random, nature. Of the five variables only No. 5, die filling conditions, exhibits the continuous drift variation that the traditional X bar-R control charts were conceived to monitor.
Variables 2 and 3, metal and die temperature fluctuations, exhibit more of cyclic drift and
are thus not well suited for periodic inspection associated with traditional SPC. A continuous
monitoring system is better suited to measure the variability of temperature-related process
variables. Monitoring within part variation will document significant temperature differences
that can occur.
Variable 5, die filling conditions, consists of the elements of the shot profile that shot monitoring equipment can monitor and measure. Capability studies can be used to establish the range
in the shot profile that the process will produce in casting production. More often than not,
changes in the shot profile due to random, constant-cause conditions are minimal compared with
the non-random conditions that are traceable to machine maintenance requirements.
Any special production requirements should be reviewed early with the die caster. Not all die
casters may be able to apply SPC to machine parameters and may have to monitor the process, or
the results of the process, through a less sophisticated method.
7-11
Quality Assurance
6.3 Capability
Capability studies have become increasingly more popular in the last several years. In the past, SPC and
capability studies were tools used mainly by machine houses, but more and more die casters are being
required to do them to qualify the die cast tooling. Capability studies can be very important in determining process ranges as well as helping to determine PPM levels. However, misuse of Cp vs. Cpk can take
away much needed process variation and tool life in the die casting operation.
Due to the pressures used in the die cast process, several variables can come into play. These
include parting line separation, mismatch at the parting line, core slide blow back and core slide
shift or a combination of the above. Normally, dimensions that are affected by these conditions
are built into the die cast die on the low side of the tolerance range. These dimensions should be
considered as a plus side tolerance dimensions only.
In addition, the die cast process can be very abrasive on the die surface causing rapid tooling
wear. Part features that are affected by this wear are normally built on the high side of the tolerance range. These dimensions should be considered as a minus side tolerance dimension only.
(USL-LSL)
Cp (6
=
x s)
(X-LSL)
Cpk
=
(3
x s)
(USL-X)
Cpk
=
(3
x s)
On as-cast features Cp should be used as the primary measurement if the dimension targeted is in
tolerance and on the right side of the tolerance range. For example a cast hole dimensioned at 2.000
+/- 0.010 (50.8mm +/- 0.25mm) checks 2.008 with a Cp index of 6.0 and a Cpk of +0.85, should be
considered a good dimension to yield maximum tool life and process repeatability.
On cored hole locations and machined features Cpk should be used as the primary measurement. For example a machined hole dimensioned at 2.000 +/- 0.010 (50.8mm +/- 0.25mm)
checks 2.008 with a Cp index of 6.0 and a Cpk of +0.85, should be considered as bad and the
size adjusted to get closer to 2.000.
6.4
PPM Levels
PPM goals and requirements are becoming increasingly popular in the procurement of die castings
and die cast assemblies. Since the part complexity, customer requirements and level of processing
contribute to the reject level, a threshold PPM level is not specified by NADCA.
Process capability studies may be used to assist in predicting PPM levels for specific castings,
secondary processes, and/or assemblies. Ultimately, the PPM goal or requirement should be as
agreed upon between the die caster and customer.
7 Porosity
It is usually necessary to address porosity when specifying die castings. While porosity specifications
are very difficult to define generically, there are existing guidelines that provide a good starting point.
Solidification begins at the surface of die castings and progresses to the center generating two
distinct zones in each wall section, as shown in Figure 7-18. The skin, which has finer grain
structure, begins at each surface and extends inward to a typical thickness of .015 to .020 in. (.38
to .50 mm). This area is usually free of porosity compared to the center of the section. The porosity
is located between the skins in the core. The finer grain structure and absence of porosity give the
skin superior mechanical properties. Skin thickness of a die casting is relatively constant and is not
a function of total wall thickness; therefore, thin-wall sections can actually be stronger and more
consistent than thick sections. The removal of the skin to a depth greater than .020 in. (.50mm) by
secondary processes, such as machining, increases the chance of exposing porosity in the core as
can be seen in Figure 7-19. These important points are not widely recognized by designers.
7-12
Quality Assurance
Dense,
chilled skin
Porosity in
center section
0.500mm
(0.020 in)
0.380 mm
(0.015 in)
0.038 mm
(0.002 in)
Dense,
chilled skin
Porosity in
center section
Figure 7-18: Skin Effect

Due to rapid solidification
in the die, a die castings
outer skin has a dense,
f ine grained structure
with a higher strength
than underlying metal.
According to Borland and
Tsumagari (2007), the skin
extends inward to a typical
depth of 0.38 to 0.50mm
(0.015 to 0.020). The
rapid solidification of the
skin tends to drive porosity
to the center of the section as
portrayed here.
Exterior or surface porosity can be identified with the naked eye, magnification or with
penetrant inspection methods.
The as-cast surface is more dense than the core, and hence, stock removal by machining should be
minimized. The die caster should be aware of critical areas as porosity can be managed to large extent
via gating, overflows, chills and various process parameters.
Castings can be inspected utilizing non-destructive inspection techniques NDT. When specified, reasonable detection levels should be employed. Non-destructive testing methods for internal
porosity detection include ultrasound (UT), radiography/X-ray (film, real-time, ADR automatic
defect recognition), eddy current (EC) and various weight techniques. Methods for external
porosity detection include visible and fluorescent die penetrant (DPI).
If porosity is a major concern due to leakage/pressure tightness issues, the employment of a
pressure test should be considered.
7
A
Figure 7-19: Various degrees of porosity exposed after machining.
7-13
Quality Assurance
7.1
Internal Porosity
Interior porosity can be detected by a range of techniques, including detection by fluoroscope, X-ray and
ultrasonic procedures. Internal porosity can also be detected in the die casting plant through sectioning
or simulated machining techniques, when the die caster is advised of the areas to be machined.
Part prints should call out the areas where only the lowest levels of pinpoint porosity can be
tolerated, areas where additional porosity can be tolerated and areas where larger porosity will
have no effect on the casting application.
Whether porosity levels are defined by X-ray or sectioning procedures, each party should retain
a sample radiograph or part section that defines the minimum acceptance standard (see fig. 7-19).
It is important that the user not specify porosity limits that are more stringent than required
for the application. It is also usually necessary to establish specific porosity standards independently for each component design. The specification of special porosity detection operations
will increase the cost of the castings.
The type of porosity may be important in defining porosity standards. A small dispersion of
smooth, round holes (salt and pepper generally less than 1mm in diameter), which are caused
by release of disolved hydrogen or entrapped gas bubbles, may have a minimal effect on part
strength and will not tend to cause leaks. Individual, non-grouped pores are generally less
than 2mm in diameter. These types of gas porosity are those most commonly found in die
casting. See figure 7-19A through 7-19E.
In critical areas of a casting. where porosity is a concern, the acceptable porosity is often
specified in the following format:
1. The maximum allowable size of individual porosity pores.
2. The minimum allowable spacing between pores.
3. The maximum allowable density of pores in a defined area (pores/distance2)
For example a note based on this format may look like:

Porosity specification in crosshatched marked areas on print: 1mm maximum porosity pore size,
2mm minimum spacing between pores, maximum of 10 pores per 12mm 2.
More jagged-shaped shrinkage porosity, caused by solidification, can cause more problems.
This is typically a part design-related issue, and is caused by heavy sections in the casting.
Shrink porosity can be interconnected and may result in leakers. The shrink porosity does not
have to be visible to cause leakers and is often microscopic in nature. Shrinkage porosity, when
exposed, can be larger than gas porosity. For instance, a typical specification for a large drilled
and tapped boss is < 2 mm on the first three threads, < 5 mm on other threads. See figures
7-19F through 7-19H and 7-19C, as well, as subsection 7.
Minimizing porosity begins with up-front planning in the design of the part and die casting die and
the management of heat in both the die and the castings. Sophisticated process control and monitoring
equipment as well as simulation software is best utilized for castings with stringent porosity requirements.
7-14
Quality Assurance
Minor
Moderate
Major
Figure 7-20B: Parting Line Break-Out placed into

3 groups.
Figure 7-20A: Parting line porosity at various severity levels.
7-15
Quality Assurance
Figure 7-21A: Example radiograph of a casting with no visible porosity revealed by radiography. This level of soundness is achievable
through consultation with your die caster and
good part design, process design and process
monitoring.
Figure 7-21B: Example radiograph of porosity

that does not impact part form, fit or function. The user should be agreeable to accepting
a specified amount of porosity in areas of the
casting where it does not impact form, fit, or
function.
Figure 7-21C: Example radiograph of shrinkage in a thick cross-section.
7-16
Quality Assurance
If specific porosity will be detrimental to the use of the product being cast, the die caster must
be informed of the areas that will require special control to reduce the incidence of such porosity.
This information must be supplied in detail at the time of the RFQ , so that measures such as
part design change requests, accountability for higher scrap or utilization of special processes,
can be taken in advance of die design and construction.
Since zero porosity is virtually impossible to achieve in a die casting, the size, nature and
location of permissible porosity should be identified by the customer, with the agreement of the
die caster. The user should be agreeable to accepting a specified amount of porosity in areas of the
casting where it does not impact form, fit or function. See figure 7-19.
Note: ASTM Nondestructive Testing Standard E505 provides reference radiographs for inspection of aluminum and magnesium die castings.
7.2
Parting-Line Porosity
It should be noted that some parting-line porosity may exist in some die castings. Whenever
possible, castings should be designed to avoid parting lines on complex functional or cosmetic
surfaces. Special measures will need to be taken when this cannot be done, such as adding changes
in the parting line, adding a CAM-type movement or a hand-removal operation to blend surfaces.
Parting line porosity should not be confused with parting line break-out (see figures 7-17A & B).
Pressure-Tight Castings
Pressure tightness (leakage) requirements for components add to die design and casting costs and
should not be specified unless required for the application.
When a pressure-tight die casting is desired, the customer should specify at the time of
quotation the pressure the die casting is expected to withstand and the relevant testing method
to be employed.
Common leak testing methods for die castings include pressurized air bubble testing (to discover
the location of the leak), gas pressure decay and mass flow testing (to determine the magnitude of
the casting leakage in pressure loss or flow rate per unit time), and helium detection probe (when
very low leak rates are required).
When the die casting is expected to withstand specified pressures, the die caster can offer
pressure testing of a statistical sample of parts, 100% sampling or impregnating of parts to meet
the pressure specification.
If machining of the pressure-tight die casting is required, it must be recognized that
impregnation may be required after machining. The die caster should be advised of the specific
areas to be machined in advance of the die design.
The die caster will not be responsible for machining, impregnating or testing costs if the machining is done by the customer. By mutual agreement, the die caster may accept for replacement or credit
the die castings that have failed the pressure test after the machining and impregnation process.
7-17
Quality Assurance
Figure 7-22: Example Advanced Product Quality Planning process f low chart.
7-18
Quality Assurance
Figure 7-23: Example New Project process f low chart.
7-19
Quality Assurance
Figure 7-24: Example New Tooling processes f low chart.
7-20
Section Contents
section
NADCA No.
Format
Page
8-2
1 Introduction
8-2
2 Using Die Casting Specification Checklists
8-2
2.1 Defining Quality Requirements
8-3
2.2 Specifying Tolerances
8-3
2.3 General Database Guidelines
8-3
3 Die Casting Dies and Production Tooling
8-4
3.1 Die Ownership
8-4
3.2 Die Life, Maintenance, Repair and Replacement
8-5
3.3 Credit
8-7
3.4 Changes or Cancellations
8-7
3.5 Die Retention and Removal
8-7
3.6 Insurance
8-7
3.7 Gaging
8-7
3.8 First-Piece Acceptance
8-8
4 Die Cast Production Part Orders
8-8
4.1 Metal and Metal Pricing
8-8
4.2 Acceptance of Orders and Reorders
8-9
4.3 Changes, Cancellations and Errors
8-8
4.4 Credit, Payment Terms and Taxes
8-9
4.5 Packaging and Delivery
8-9
4.6 Limitations on Inspection Procedures
8-10
5 Purchased Components
8-11
5.1 Cast-in-Place Inserts
8-11
5.2 Inventory Costs
8-11
6 Price Adjustments
8-11
6.1 Quotations and Metal Market Pricing
8-11
6.2 Labor and Operating Costs
8-12
7 Patent Obligations
8-12
8 Intellecual Property
8-13
9 Warranties Covering Die Castings
8-13
9.1 Extent of General Warranty
8-13
9.2 Limitations of Warranty
8-13
10 Product Liability
8-13
11 Production and Finishing Specification Checklists
8-14
Casting Production Specifications
C-8-1-15
Checklist
8-15
Casting Finishing Specifications
C-8-2-15
Checklist
8-16
8-1
1) W
ho owns the die cast die?
See page 8-4, Die Ownership.
2) A re there checklists available that can be used for cast or finished specifications?
See pages 8-14 and 8-15 for checklists.
3) How long do dies last?
See page 8-5 and 8-6, Die Life, Maintenance, Repair and Replacement.
4) A re there any recommendations for creating CAD data files?
See page 8-3, General Database Guidelines.
5) W
hat is involved with die maintenance/repair/replacement?
See page 8-5 and 8-6, Die Life, Maintenance, Repair and Replacement.
1 Introduction
In specifying die cast production, the purchase contract can be viewed as the purchase of a
comprehensive engineering service from the die caster who will use the purchasers tool to
convert metal to the precise form desired by the purchaser.
The die caster will usually provide other important services, such as designing, constructing
or maintaining the tool and performing machining and surface finishing operations on die cast
parts. Sub-assembly services may also be provided.
The proposal and subsequent order for die castings sets forth a contract embodying the
business practices governing a transaction in which custom engineered parts will be supplied on
a continuing basis. Quality production of a high volume of custom parts, at the most economic
level, involves a thorough understanding of the variables of the die casting process, its tooling
requirements and related trimming, secondary machining and finishing operations.
The physical properties and constants of metals and alloys used for die castings are set forth
in Alloy Data (Section 3 of this volume) and should be referred to with other accepted metallurgical specifications.
Aid in determining the detailed part design requirements to be specified for cost-effective
production can be obtained from the Engineering and Design standards and guidelines in this
volume (Sections 4, 5 and 6), together with other recognized engineering data. If geometric
dimensioning is not being used on part prints, GD&T (discussed in relation to die cast parts in
Section 5) is strongly recommended for optimizing quality and lowest costs.
Tooling (Section 2) and Quality Assurance (Section 7) should likewise be reviewed well before
drawing up final product specifications.
Of equal importance to careful specification are the commercial arrangements which affect
the buying of die castings. These trade customs have evolved from a half-century of industrywide production experience and have generally been accepted as good business practice. The
commercial arrangements are normally found in the proposal and acknowledgement forms
used by the North American die casting industry.
These specialized inter-relationships, among others, govern the ability of the custom producer to supply die castings to specifications on prearranged quantity schedules at competitive
levels on a continuing basis. They are described in this section together with convenient die
casting product specification checklists.
Using Die Casting Specification Checklists
The C-8-1 Checklist (Die Cast Product Specifications) and C-8-2 Checklist (Die Cast Surface
Finishing Specifications), which appear at the end of this section, can help the purchaser to more
clearly define the die casting requirements that will impact final costs. They can serve as a production
guide to help provide accurate communication between the purchaser and the die caster, avoiding
8-2
misunderstandings later. The die caster should review these specification levels with the purchaser
to assure that the most cost-effective level is selected and, if necessary, provide samples of various
specification levels.
2.1
Defining Quality Requirements
The checklists also mention the use of SPC and other inspection requirements. It is highly desirable to define such requirements so there is no question about record-keeping responsibilities.
While most die casters use these techniques regularly, some purchasers have special requirements
(ie. critical feastures) that must be defined early in the process.
When using statistical techniques for quality control, it is important for the purchaser to
specify the parameters when requesting a price quotation. For example, general definitions of
process capability, such as Cpk, can affect tooling dimensions that are built towards one side
of the tolerance to allow for future die wear. These dimensions can vary in one direction only,
as in the outside dimensions of a cavity (see Moving Die Components Section 4A). When
applying general definitions in this situation, the tool will appear to be out of limits, while it is
actually built to high quality standards for long life.
It is most important that agreement on procedures be reached prior to establishment of the quality
standards. The costs for the quality level of a feature are calculated by the die caster during the
quoting process, and any changes in standards at a later time may require a revision to the quotation.
Many of the specifications, such as the quality of a surface finish or the severity of internal
porosity, are subjective. The methods of establishing subjective standards can vary considerably, but
it is always beneficial to spend the effort required to define the standards as closely as possible.
One way of defining subjective standards is to define borderline acceptable and acceptable
samples, which should be retained as limit samples by the customer and the die caster. In addition, it is desirable to have pictures or a complete written description of the defects that would
cause rejection. Such provisions can be improved upon during the initial production phase.
2.2
Specifying Tolerances
It is well known that the die casting process can achieve very high dimensional precision. The
Engineering & Design Tolerance Standards for coordinate dimensioning of parts to be die
cast (Section 4A) are presented at two levels: as Standard Tolerance and as Precision Tolerance
specifications. Most die casters can improve on the Standard Tolerances, but a cost penalty in
increased cycle times will often be the trade-off.
Tolerance improvements are most directly related to part shape. If tolerance requirements are clearly discussed in advance with the die caster, precision tolerances can often be
maintained for a cast part with significant improvements in product performance and reduced
secondary machining and finishing operations.
Machining processes should also be considered well before any order for the tooling is
released. A careful evaluation of machining requirements can lead to a redesign for net-shape die
casting or near-net-shape production, with a reduced number of operations or setups.
2.3
General Database Guidelines
Computer Aided Design (CAD) databases usually consist of a two-dimensional drawing (2-D)
and a three-dimensional model (3-D). Software compatibility is a common problem between
customer and die caster. To expedite communications, the die caster and customer should be
aware of each others CAD software capabilities early on in the project. In the event that the
die caster and customer do not utilize the same software packages, universal file formats can
be used to communicate. Although there are many available, the most common formats are
DXF or DWG (for 2-D drawings) and IGES or STEP (for 3-D models). Often, translation
software is needed to convert files into the appropriate format.
When databases are utilized for quoting purposes, these general guidelines apply:
1. If only a 2-D drawing is provided, it should contain dimensions and general views of the part and
major features. Physical properties such as mass and part volume should be included as well.
8-3
2. If only a 3-D model is provided, the die caster should be able to retrieve dimensions and
properties from the model.

3. Secondary operations, such as machining, can be included in the database or supplied
separately.
Some general requirements when databases are being utilized for tool construction:
1. When only a 2-D drawing is provided:
1.1. Drawing should contain complete dimensions of all features.
1.2. Parting line, draft, radii, datums and tolerance (dimensional and geometric) requirements
should be clearly defined.
1.3. Secondary operations that are to be performed on the part and other requirements
should be clearly stated.
2. When only a 3-D model is provided:
2.1. All necessary draft, parting line and radii should be included in the model. Ideally the
3-D model will indicate machined surfaces.
2.2. Lines and surfaces of the model should be connected within 0.001.
2.3. The 3-D model should be accompanied by a limited dimension part print that contains
all tolerancing information and shows any secondary machining to be performed.
An incomplete database could result in an inaccurate quote and possibly require considerable
database manipulation, which leads to additional cost and extended lead-time. The die caster and
customer should also indicate whether the 2-D drawing or the 3-D model controls the project.
Die Casting Dies and Production Tooling
Any die casting can be produced in a number of different ways and every die casting plant possesses different equipment and utilizes a range of production techniques. Optimum economy
and maximum efficiency for the production of any die casting, therefore, must be considered in
the light of the particular equipment with which it will be produced. The experience, technology, skill and ingenuity of the die caster are all involved in selecting the method of production
on which the proposal is based.
Each die caster sells die casting dies, trim dies and specialized production tooling on its own individual terms and conditions. Normally, these terms provide for an advance payment for dies and tooling,
with the balance paid upon receipt of, or approval of, a sample produced from the dies and tools. Length
of time for approving parts to be 30 days if not otherwise agreed upon between die caster and customer.
3.1
Die Ownership
Generally, the purchaser of die castings will retain ownership of the die casting die, even though
the die remains with the die caster. It has also been the custom that the design and construction
of the die casting die are performed by the die caster to its own specifications, even though the
purchaser owns the die. The custom generally works to everyones advantage.
The practice has developed because most purchasers lack the extensive experience and
expertise required to design and build a die casting die that will produce acceptable castings.
There are also a number of features of the die that need to precisely match the die casting
machine selected by the die caster.
These die construction and ownership practices are generally being maintained today, although
other options are available for the purchaser. The increasing technical capacity of designers is
making it possible for a knowledgeable purchaser to contract for the design and construction
of a die from a tooling vendor, then select a die caster to run the tool. However, this procedure
can potentially create a number of serious conflicts with the eventual die caster. For example, if
the castings are of low quality, who is responsible? The problem could stem from die design, die
construction or production operations.
Consequently it is preferable for the die caster to be responsible for die design and construction. In addition to eliminating questions of responsibility, this procedure also ensures that the
die will match the casting equipment. In addition, the die caster has a vested interest in building
a high-quality die that will give few problems in production.
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The die casting die, usually owned by the purchaser, is housed and maintained at the die
caster. The die caster will be responsible for loss or damage to the die and tooling while housed at
the die casters facility. Some die casters offer the option of joint ownership of the die. In either
case, there are some considerations that should be addressed during the purchasing discussions.
An ownership record should be established by both parties, which will include a description
of the die and all additional components of the die. Each die should have a method of identification, which is best done with engraving or welding (riveted tags can come off). Typically a
number is assigned to the die by the die caster, which is engraved on the die, slides and cores and
included in the purchasers record of the die.
All components purchased originally with the die should be noted in the record, such as shot
sleeves or extra slides or cores. These components usually wear out much more rapidly than the
rest of the die and they may be worn out and unavailable if the die is claimed by the purchaser.
The question of Tool Ownership as well as Replacement is often overlooked when general
discussion begins at the start of a possible new project. Since there are multiple types of tools
available for the die cast process the following descriptions for tooling and ownership is to
provide a starting point for those decisions.
New tools are generally paid for by the Customer, the Die Caster is responsible for normal
maintenance and care (as the caretaker), the customer (as the owner) for replacement. It is the
responsibility of the die caster to inform the customer of any atypical maintenance or care
required. If the customer elects not to follow the maintenance advice of the die caster the quality
of the part could suffer. In todays rapid development world sometimes who owns what is not
clear. In the following cases an example will be given as to typically who owns what portion of
the tool.
1) R
apid Tooled projects frequently use a tool (mold base) that is owned by the die caster
and becomes a type of Universal Holder for Die Cavity inserts (for multiple customers).
The inserts that are used to make the part configuration are owned by the customer and
frequently will have a shorter tool life than Production made tooling.
2) F
or Unit Dies, the Master or Universal Holder (as above) is usually owned by the Die Caster
and the individual units and their inserts are owned by the Customer. As long as a Unit
Die is the equivalent of an Industry standard it should be able to move to a new die caster if
needed without major cost factors involved.
3) Dies by themselves are owned by the Customer and may have different shot life attached to
them based on part design and function.
Replacement is usually limited to the cavity inserts but in certain cases could be the entire die. Normally the customer is notified at the 1/2 life that replacement is needed so that enough time is allowed to
get the replacement components approved before the original tool wears out. This can be paid for at the
time of construction of the replacement or in cases of a very high volume part an amortization account
may have been set-up. This type of account allows for a small amount to be added to the part price that
will cover the cost of the replacement when needed. It becomes the Die Casters responsibility to manage
tool replacement and to notify the Customer when new replacements are submitted for approval.
Tooling Amortization must be started at the time of the fist part being produced for sale so that the
account can cover the cost of replacement start and the balance due at approval. If it is not started at
this time the tool may have to be pushed beyond normal life to pay for a new tool and to not interrupt
Customer production. This usually results in added operations to the part which can increase costs. This
process does not work with inherited tooling because of questions concerning actual shot count on the
tool but can be applied after the first replacement is completed. Either the Customer or the Die Caster
can be holder of the amortized funds for replacement but usage terms need to be clearly defined.
The Die Caster and the Customer need to agree on both the initial tool and replacement
plans (as needed) and payment terms at the start of the project so that on-going needs are met
and ownership is clear.
3.2
Die Life
The purchaser should be aware that the life of a die can be unpredictable. Die life is a function of
many factors. Among them are part design, part configuration in the die, part quality expectations,
8-5
release quantity, type of tool steel used for the die, the heat treatment of the die and the type of
alloy being die cast.
Even when the die caster makes every effort to extend die life, early failure is still possible. It
is also possible for a die to have an unpredicted very long life. An understanding of expected die
life should be discussed in the initial phases of a project.
Progressive die casters can provide tool steel specifications and heat treat specifications that
have been developed through extensive NADCA research programs. It is recommended that the
purchaser reference these specifications for the building and heat treating of the casting die. The
specifications include recommendations for stress relief during machining, the removal of the
white layer after EDM operations and a number of other considerations.
When tooling is procured through a reputable die caster, tooling costs may be somewhat
higher than if a purchaser dealt directly with the tool builder. The die caster will be closely
involved in evaluations and decisions that will translate the product design into the optimum die
casting die for successful production. The increased costs almost always represent a bargain in
terms of overall costs during the life of the die.
An inexperienced purchaser who purchases tooling purely on a cost basis will find that the
costs over the life of a die are significantly higher because of a lower-quality tool, although this
will not be immediately apparent when the tool starts running. It cannot be emphasized too
strongly that good quality tooling will cost more in the beginning but pay for itself many times
over in the life of a typical die casting die.
Note: Computer
software is available
for flow simulation,
thermal and distortion
analysis.
8-6
3.2.1 Die Maintenance, Repair and Replacement
The responsibility and criteria for maintaining tooling, on the one hand, and replacing the
tooling, on the other, should be understood. In some cases, the die replacement cost is requested
to be amortized into the piece price. The most common way of structuring this portion of the
contract is for the die caster to provide minor maintenance, and the purchaser to provide major
repair and replacement.
Minor maintenance is generally described as run-to-run maintenance of a serviceable die to
maintain die casting production. Major maintenance would cover the replacement or rebuilding
of an entire die cavity, die section, or complex core slide that makes up a significant percentage
of the casting detail, or major die resurfacing. Most die casters have a preferred way of handling
maintenance and it should be made clear.
The rapid wear components should be covered in the die maintenance understanding between
the purchaser and the die caster. These components are frequently replaced by the die caster,
although each purchaser should expect to make an individual agreement for each casting. If
the components are replaced by the die caster, ownership usually remains with the die caster,
although this can vary for individual agreements.
The purchaser should review the die maintenance practices of the die caster and agree on the
expected maintenance. For example, if the purchaser expects the die to be stress relieved after a
certain number of shots, then the die caster should be aware of this requirement so that it can be
included in the costs.
Die preheating practices, gating design and die temperature control are particularly
important to long die life. Reviewing these practices may be difficult, but there are some steps
a purchaser can take.
1. The purchaser should ascertain the die preheating practices of the die caster. The best results
are achieved by preheating dies to a specified temperature, depending on the alloy being
cast, before the first casting is made.
2. Smooth metal flow at the correct velocities from a carefully designed gate is important to
reduce the die erosion at the gate, as well as having a significant effect on casting quality.
Die erosion can be repaired by welding, but the onset of welding significantly reduces the
ultimate life of the die.
3. The die caster should be able to discuss the use of good die design practices with the
purchaser. A die caster using trial and error without calculations for gating will have many
more problems with die erosion and part quality than one who uses calculation techniques
developed by NADCA or other authorities.
4. Die temperature control, involving careful cooling line control and proper cooling line
placement, will influence casting cycle time and have an important effect on casting quality.
Working with a quality die caster assures the purchaser that all aspects of die design and
construction follow practices that maximize production as well as die life.
3.3 Credit
The die caster generally reserves the right to change his terms of payment if a change in the customers
financial condition requires it. Such changes are usually requested in writing and, when necessary, may
require the die caster to stop design and/or construction pending agreement.
3.4
Changes or Cancellations
If any changes are required by the purchaser to finished die casting dies or production tooling
which deviate from the original print and/or model provided for the dies and tooling at the time
of quotation, the die caster reserves the right to requote the quality, expected die life, cost and
delivery of the tooling. Any changes to the order must be agreed to by the die caster, in writing.
The die caster will usually require some payment for cancelled orders. Payment is necessary to
compensate the die caster for costs of work in process to the date of cancellation and commitments made by the die caster for purchases relating to the order.
3.5
Die Retention and Removal
It is customary for the die caster to retain control and possession of die casting dies and production tooling. Since the full cost of engineering, designing, obtaining, and maintaining the die
casting dies and production tooling is not fully reflected in the charges to the purchaser for these
items, an additional charge may be necessary for these unreimbursed costs if the die casting dies
and production tooling are removed prematurely from the die casters plant.
It is also customary to allow die casting dies and production tooling which have not been
used for three consecutive years for production of die castings to be scrapped following proper
notification, via certified mail, to the purchaser by the die caster.
Rules for the accessibility of the die should be established. If the die is to be claimed by the
purchaser, it should be available after notice has been provided, and all outstanding invoices due
the die caster are paid in full.
3.6 Insurance
It is customary for the insurance of die casting dies and production tooling to be the responsibility of the purchaser, unless specifically agreed upon, in writing, to the contrary.
Die casters normally have liability insurance protection against fire and theft or vandalism. However,
fire insurance usually excludes tools, which do not burn, except for the clean-up costs following a fire.
Insurance should be reviewed in each case, and business interruption in case of fire may need to be
considered. Die casters will provide workers compensation insurance as required by law.
3.7 Gaging
Good gaging is critical to obtaining good quality parts, both during the process and at final
acceptance, and can also help reduce part cost, especially if a casting is heavily machined. It is
important that this aspect be discussed early in the project.
The die caster can be expected to furnish standard gages. The purchaser is expected to furnish any
special gages needed in the inspection process, such as those required for determining conformance to
feature and location specifications and any gages needed for functional or statistical requirements.
All gages and gaging methods should be agreed upon in advance by the purchaser and die caster,
including any need for duplicate gages. This will aid in both part function and fit, in instances where the
die casting will be mated or assembled with other parts not manufactured by the die caster.
8-7
3.8
First-Piece Acceptance
After the first die cast samples are received from a die casting die, the die caster or purchaser will
usually be required to measure the samples and verify that they meet specifications. Modifications
from the original print which have no effect on part function or appearance can be discussed at this
time to ensure that high production rates can be maintained and premature die maintenance avoided.
Procedures for handling changes in the print specifications for the die casting should be
agreed upon. Any costs and delivery delay incurred by such changes should be quoted by the die
caster immediately after they are received. Authorization for the changes should be given by the
purchaser in writing on each change order.
Die Cast Production Part Orders
The commercial terms of the contract items and conditions between the purchaser and the die
caster for die cast part production are discussed below. Note that the trade customs outlined
represent the historic and customary practices prevailing in the die casting industry. Contract
forms of individual die casters will vary in some details. A model of terms and consitions can be
found at www.diecastingdesign.org/terms/
4.1
Metal and Metal Pricing
Quality metal is the foundation for good castings. Even a chemical analysis does not fully define
all the metal quality specifications that are necessary for good die casting. Low-cost, low-quality
metal cannot be expected to meet all die casting requirements.
For example, when aluminum or magnesium alloy does not meet established criteria, machining
may be more difficult or surface corrosion accelerated. When zinc alloy does not meet established
criteria, mechanical properties will be progressively and seriously reduced in use with time.
Metal price is commonly established from quotations from an approved metal supplier, or
based on known industry indicators such as the daily American Metal Market, the London
Metal Exchange, Platts or other major markets. If the purchaser elects to use an industry
indicator, he may forfeit the advantage of spot metal buys at lower than market price.
4.2
Acceptance of Orders & Reorders
4.2.1 Acceptance of Orders
Proposals for the production of die castings are prepared on the basis of the specifications and
prints known at the time of estimating. Die casting proposals are, therefore, for immediate
acceptance on the basis specified. Similarly, since orders are accepted on the basis of the requirements known at the time of the order, changes from the original proposal on which the order is
based may result in the need for price adjustment for the parts. The die caster reserves the right
to review all orders before acceptance.
The proposal, the order and its acceptance, signed by an authorized representative of the die
caster, constitute the entire contract with the exception that, when any provisions of the order
conflict with the proposal, the proposal and acceptance always prevail. Modifications, changes,
additions, cancellations or suspensions of an order are not binding upon the die caster, unless
accepted in writing by an authorized representative of the die caster and upon terms that will
indemnify him against all loss.
4.2.2 Reorders
Reorders for die castings are covered by the same conditions as was the original order, provided
no revised proposal and acceptance has intervened. Pricing of reorders will, of course, be affected
by quantity alloy, labor and other costs prevailing at the time the reorder is placed.
8-8
4.3
Changes, Cancellation and Errors
4.3.1 Changes or Cancellation
Any changes to the order deviating from the original basis upon which the order was accepted
must be agreed to, in writing, by the die caster. These changes may result in the adjustment
of prices. Changes could include, but are not restricted to, delivery dates, quantities, release
dates, part prints, etc.
The die caster usually will require some payment for cancelled orders. Payment is necessary to
compensate the die caster for costs of work in process to the date of cancellation and commitments made by the die caster for purchases relating to the order, including dedicated equipment
specifically acquired for a cancelled project.
Any change to the delivery schedule or release dates beyond 90 days must be subject to
negotiation between the die caster and the customer.
4.3.2 Errors
Clerical errors are, of course, subject to correction regardless of whether they favor the buyer or
the seller and enforceable if discovered within a period of one year.
4.4
Credit, Payment Terms and Taxes
4.4.1 Credit
The die caster generally reserves the right to change terms of payment if changes in the customers
financial condition requires it. Such changes are usually requested in writing and, when necessary,
may require the die caster to stop production or suspend shipment pending agreement.
4.4.2 Terms of Payment
Each die caster sells its products on its own individual terms and conditions. Shipments are
generally FOB the city in which the die casting plant is located. Payment is normally net 30 days
with provision for metal market and escalation clauses.
4.4.3 Taxes and Duties
Sales or use taxes, excise taxes, taxes on transportation, other direct taxes and applicible duties
are the responsibility of the purchaser whether such taxes are federal, state or local.
4.5
Packaging and Delivery
4.5.1 Shipping Tolerances
Since the die caster cannot determine in advance the exact loss factor in a particular run, it is
generally recognized that he may manufacture and ship 10% over or 10% under the number of
die castings ordered or released. If no deviation is to be allowed, with pricing affected accordingly, this should be so specified in the purchasing agreement.
4.5.2 Packaging
Die castings are generally packed in bulk as the most suitable and economical method. Any
special requirements, such as specifying layer packed, separated or cell-packed shipments, must
be communicated to the die caster in the RFQ ; otherwise a price change may be required later.
If recyclable packaging is required, it should be carefully spelled out in the quoting phase. While
this type of packaging can have a positive impact on pricing, it may increase up-front costs. The
die caster will be responsible for cleaning and reusing recyclable packaging.
8-9

4.5.3 Deliveries
Unless otherwise specified, deliveries of die castings generally begin as soon as the die casters
schedules permit and, in the case of a new die, after approval of samples. Deliveries are made at a
rate approximately equal to the capacity of the tools until orders are completed. The purchaser selects
the method of delivery and, unless otherwise specified on the purchasers order, the die caster will
use his best judgement in routing the shipment and seeing that deliveries are effected as specified.
Acceptance of the goods by the carrier shall constitute a delivery. Any charges in connection with
postponement or cancellation of delivery are the responsibility of the purchaser. The purchaser will
also be responsible for any additional costs of expedited or other special transportation as result of
changes in delivery schedules not caused by die caster.
Penalties upon the die caster for delayed delivery, whatever the cause, are not normally acceptable unless agreed upon at the time the order is being placed.
Many die casters today can provide an electronic connection to high volume purchasers to
facilitate placing orders, as well as provide bar coding. It is frequently desirable to anticipate
emergencies and provide for backup tooling, a small amount of emergency inventory or some
other way of addressing the catastrophic failure that can occur in any volume production process
based on sophisticated tooling.
4.5.4 Lot Size versus Cost
Because of the cost of setup, die casting is usually a high-volume process where the cost of a
small lot is significantly increased by setup costs. It is therefore imperative that lot sizes be
considered in the discussions of the purchasing contract. Each die caster will have his own costs
for setup, so the break-even point for minimum lot sizes will vary among die casters. Some
purchasers use consignment inventory agreements to address the reality of die setup costs and
tooling life factors that are adversely affected by the short runs.
Lot size should be considered in the early stages of determining the tooling requirements.
For example, in some cases fewer cavities on a smaller die will result in lower tooling costs,
lower setup costs and a smaller economical lot size. This may be more desirable even though the
piece-price may be slightly higher.
If small lot sizes are required often, quick setup aids, such as quick-disconnects, can be built
into the tooling. Advising the die caster of small lot requirements at the time of quotation will
enable him to optimize the use of these aids.
It is desirable for the purchaser to take time to explore the options of economical lot size,
costs of maintaining inventory and tooling options during the tooling quotation phase. Since
there may be many options, it is suggested that the purchaser provide the die caster with those
considerations that are important for the project and let the die caster propose several options.
This will allow the die caster to maximize the efficiency of the equipment available in his plant
and provide the most economical quote to the purchaser.
4.6
Limitations on Inspection Procedures
4.6.1 Prints and Approved Samples
Die castings may not be rejected because of variation from print dimensions if they are made to,
and are unchanged from, approved samples with respect to dimensions, finish and analysis. When
the purchaser has specified or approved the design, failure with regard to function or fitness for use
shall be the purchasers responsibility. If sample die castings have not been approved and conflicting models and prints have been submitted, the basis of acceptance shall be agreed to in writing.
4.6.2 Accuracy
Die castings may not be rejected if they vary from finished sizes or dimensions within limits agreed
upon. Where a very close tolerance or particular dimensional accuracy is specified, the permissible
variations shall be agreed upon before die work is begun. In the absence of applicable standards,
tolerances will be subject to the commercial variations generally prevailing in the industry.
8-10

4.6.3 Inspection and Sampling Procedures
If specified and specifically acknowledged and agreed to by the die caster, die castings can be
inspected on the basis of statistical quality control or other sampling procedures.
Use of statistical quality control standards and other related procedures require specific
detailing by prior mutual agreement on all aspects involved.
4.7 Compliance with Laws

Die caster will comply with applicable laws, rules and regulations of the country where the
casting is made. Die caster will provide customer with material safety data sheets and, upon
request, provide other information reasonably required in order to comply with applicable
laws.
Purchased Components
Innovation in the design of die castings and flexibility in the industrys manufacturing process
have led to the use of purchased components for insertion or assembly by the die caster. The
procurement and subsequent responsibilities for the delivery and quality of such components lies
with the purchaser of the die casting unless otherwise agreed upon and included in the quote
and the order. These components may be insert cast as an integral part of the die casting or
may be assembled to the die casting in a separate operation.
5.1
Cast-in-Place Inserts
If the finished casting contains cast-in-place inserts, the responsibility of providing them to the
proper specifications should be clearly defined. The design of the purchased component is the
responsibility of the die casting purchaser and is subject to approval by the die caster. In many
cases the clearances in the die will require that the insert tolerances be tighter than the purchaser
would normally supply for the required end use. If the purchaser is supplying the inserts, provision must be made to ensure that all supplied inserts are within tolerance. An out-of-tolerance
insert can seriously damage the die.
5.2
Inventory Costs
Regardless of who purchases an additional component, there must be consideration given for
in-process spoilage and rejects. As a result, the quantities of purchased components will always
exceed the number of die castings purchased. It is understood that there are costs associated with
handling, storing, counting and inspecting of purchased components. Inventory of purchased
components required to meet the die casting purchasers delivery schedule are the responsibility of the die casting purchaser. The labor cost for inserting or assembling the component is
normally included in the quoted piece price.
Price Adjustments
Because of the job-shop nature of production and the variation in product design and specifications, the prices for die castings are determined by the use of price estimating formulas.
Each die caster employs an individual pricing formula constructed in accordance with their individual
methods and costs. All price estimating formulas contain a number of factors which may require
adjustment, upward or downward, because of conditions beyond the control of the estimator. Significant
unexpected increases in the cost of either natural gas and/or electricity may result in negotiated energy
surcharges per mutual written agreement.
8-11
6.1
Quotations and Metal Market Pricing
6.1.1 Order Quotations
Order quotations for die cast products, and die casting dies and production tooling necessary to make
the die cast products, are normally valid for a fixed period of time. After this time has expired, the die
caster reserves the right to requote based upon price adjustment provisions as discussed above.
To establish a uniform basis of comparison, the estimated weight and monthly and/or yearly
quantity requirements should be specified when soliciting quotations, and it should be requested
that the material cost be itemized.
6.1.2 Metal Market Pricing
Prices for die castings are based on the die casters prevailing cost for the alloy specified on the
day the estimate is prepared. In some instances, the die casters quotation may make reference to
various published alloy prices or other indicators. The cost for the alloy is subject to fluctuation
beyond the control of either the purchaser or the die caster and the actual price charged for the
die casting will reflect the changes required to adjust for all metal market variations. Similar
adjustments may be made on each release and/or reorder.
6.2
Labor and Operating Costs
6.2.1 Labor Costs
Many die casting dies are in production over extended periods, often over many years. For
this reason, the piece-part labor cost may change over the life of the order. If piece-part labor
costs change after the date of the original price estimate, it is generally necessary to change the
piece-part price for future deliveries.
Customer schedules often are expanded and sometimes require production beyond the normal
schedules of the die caster.
Since all die casting prices are estimated on the basis of production at straight-time rates, an
adjustment is generally required if premium labor rates are necessary to meet the customers
expanded needs.
Die casting price estimates and quotations reflect labor costs based on continuous operation for
the quantity specified for any delivery release. Reductions in scheduled deliveries or production
interruptions by the customer, may affect labor and other piece part costs. In such cases, a price
adjustment may be necessary.
6.2.2 Operating Costs
Costs of outside services (such as painting, plating and machining), or of purchased supplies
and components (such as inserts, packing materials and fasteners), or action of governmental
or regulatory agencies may cause periodic increases in the costs of manufacturing. These added
costs must be reflected in changes to quoted prices. Also, changes in acceptance criteria by the
customer may significantly affect the die casters operating costs, making an adjustment to the
part price necessary.
Patent Obligations
Die casting is essentially a conversion process by which metal shapes are produced for a
purchaser. Therefore, if a die casting infringes, or is claimed to infringe on any letters patent or
copyright, the purchaser must assume the responsibility involved.
While the die caster does provide input into the design of the customers component for die
casting manufacturing feasibility, the die caster is not responsible for the design or functionality
of the customers product or device or for the design of the die casting as part of such product
or device. The purchaser of die castings is liable for his own product or device and for all patent
infringement claims relating to it or any of its parts.
8-12
Die casting proposal and acknowledgment forms generally include clauses which provide that
the die caster shall be indemnified and held harmless of and from all expenses arising from all
such claims. When patents, design or otherwise, are involved, they should be specifically called
to the attention of the die caster.
Intellectual Property
Die Caster is not required to provide any intellectual property used to produce parts for the
purchaser. Purchaser has the right to use parts in purchasers product.
9
9.1
Warranties Covering Die Castings

Extent of General Warranty
Die casters, like other responsible manufacturers, stand behind their product. However, it should
be understood that the die caster in assuming this proper responsibility focuses its engineering
efforts upon the die cast manufacturing feasibility of the component, rather than the components product function which is the responsibility of the purchaser.
In general, die casters agree, at their option, to correct, replace or issue credit for, defective die
castings, subject to specific limitations and exceptions. Reference NADCA Terms and Conditions for more details on warrenties.
9.2
Limitations on Warranty
9.2.1 Processing After Delivery
No warranty attaches to a die casting which has been altered, machined or finished after delivery
to the purchaser by the die caster.
9.2.2 Reasonable Time
No claim for defective die castings will be recognized unless made in writing within 90 days (or
as agreed upon between die caster and purchaser) after delivery.
9.2.3 Returns
Die castings claimed to be defective are not to be returned to the die caster without specific
approval and inspection by the die caster. Returned goods accepted by the receiving department
of the die caster are not exempted from the right of the die caster to inspect the die castings or to
determine the extent, if any, of his liability.
9.2.4 General Limitations
Losses, damages or expenses arising from the use of a die casting, or labor costs or other charges
incurred outside of the die casters plant, or transportation costs, as well as losses due to other
causes, are not acceptable basis for claims against die casters under the warranty provisions. The
Warranty as stated in paragraph 8.1, above, is limited to the repair or replacement of defective
die castings or the issuance of credit for their return as stated.
8-13
10 Product Liability
Die casters cannot be expected to have technical knowledge relating to the end product of the many
industries they service. While they may freely offer design services to make a product easier to
manufacture, at no time does this imply a knowledge of the strengths, stresses or other forces that
may be induced in the products end use. This must be exclusively the liability of the buyer and design
suggestions are offered by the die casters with this understanding.
The die casting industry has always maintained the position that a die caster is not liable for the failure
of a die casting in a buyers product, if the part furnished to the buyer meets the prescribed specification.
Die casters accept the responsibility of manufacturing a part to the buyers specifications within the
agreed acceptance level. This means the buyer will accept a percentage of parts that do not conform
to the specifications. Die casters cannot be held liable for any failure in the end product because of the
decision on the part of the buyer to use statistical quality control in its incoming inspection.
If a buyer approves a sample for production of parts that do not meet specification in any
way, this approval constitutes a change in specification and the die casters responsibility is then
altered to only meet this altered specification.
It is anticipated that the buyer will indemnify and defend the die caster from any damages or
claims arising from the use of die castings or other goods produced to the buyers specifications.
11 Production and Finishing Specification Checklists

The C-8-1 Checklist (Die Cast Production Specifications) and C-8-2 Checklist (Die Cast
Surface Finishing Specifications) appear on the following pages.
It is recommended that, prior to final quotations, and always before any die design commences,
the casting requirements defined by these checklists be reviewed with the die caster, together
with the specifications and procedures listed in Section 7, Quality Assurance. All of these
items impact final costs and should be thoroughly discussed to assure accurate communication
between the purchaser and the die caster.
8-14
NADCA
C-8-1-15
CHECKLIST
Casting Production Specifications

To be used in consultation with your caster (Use in combination with Checklist C-8-2)*
Checklist for Die, SSM and Squeeze Casting Production Part Purchasing
This Production Checklist provides a convenient method for assuring
important factors involved in purchasing cast parts are evaluated and
clearly communicated between the purchaser and the caster.
It should be used as a supplement to the essential dimensional
and alloy specifications detailed on part prints submitted for
quotation, since the listed factors directly affect the basis on which
the casting quotation is made. The checklist may be reproduced
for this purpose. Your caster will clarify any item requiring further
explanation.
This checklist provides a numbering system in which the lowest
numbered description for each requirement can be met at the lowest
production cost, as follows:
This checklist is for use in consultation with your die caster

prior to estimating production
costs. Use in combination with
the Finishing Checklist C-8-2.
Also review Checklists T-2-1A
and T-2-1B, for Die Casting
Die Specification, in Section 2.
No. Cost Effect
1
2
3
4
Most economical basis for production

Involves additional work which may
affect cost
Additional work which may increase cost
Special Requirements which may
increase cost
Part #
Casting
Cleanliness
Cast Surface
Finish
1 Mechanical quality finish is not significant

2 Painting quality streaks and chill areas coverable with paint
3 Highest quality for electroplating, decorative finishing, O-ring seats
Metal Extension
(Flash) Removal
Parting Line
External Profile
Metal Extension
(Flash) Removal
Cored Holes
1 Flash not removed

2 Flash trimmed to within 0.010 (0.25 mm) of die casting surface
3 Flash to be machined
Metal Extension
(Flash) Removal
Ejector Pins
1 Not removed (See NADCA Guidelines G-6-4)

2 Crushed or flattened (See NADCA Guidelines G-6-4)
3 Removed from specific locations
Pressure
Tightness
1 No requirement
2 Pressure-tight to agreed-upon psi (kPa). Testing medium: ___________________
3 Other arrangements to be agreed upon
Flatness
A
B
F
G
H
I
J
1
2
3
4
1
2
3
4
1
2
3
4
Some residue and chips not objectionable

Shop run blown reasonably free of chips but not degreased
Clean, dry and free of chips
Special requirements
No die trimming break off gates and overflows

Die trimmed to within 0.0150 (0.38 mm) of die casting surface (See NADCA Guideline G-6-5)
Hand filed or polished flush with die castings surface
Customer defined requirements (such as thermal, tumble or vibratory deburring, or shot or grit blasting)
No requirement
To NADCA Standard specification tolerances (S-4A-8)
Critical requirement to NADCA Precision specification tolerances (P-4A-8)
Customer defined requirements
Dimensions
1 Normal: per NADCA Standard specification tolerances

2 Semi-critical: Precision tolerances on specified dimensions, others Standard
3 Critical: Special tolerances to be agreed upon
Customers
Receiving
Inspection
1 No unusual inspection requirements no Statistical Quality Control

2 Statistical quality control: Acceptable at Cpk 1.33 or higher (or AQL over _________________)
3 Statistical quality control: Acceptable at Cpk 2.0 or higher (or AQL over __________________)
Packaging
1
2
3
4
Not critical bulk packed

Layer packed, with separators, or weight restriction
Packed in cell-type separators or individually wrapped
Customer defined requirements
* The specification provisions and procedures listed in Section 7, Quality Assurance, should also be addressed.
Publisher grants permission to reproduce this checklist as part of a casting Request for Quotation or Production Specification.
8-15
NADCA
C-8-2-15
CHECKLIST
This checklist is for use in consultation with your die caster
prior to estimating production
costs. Use in combination with
the Finishing Checklist C-8-2.
Also review Checklists T-2-1A
and T-2-1B, for Die Casting
Die Specification, in Section 2.
Casting Surface Finishing Specifications

To be used in consultation with your caster (Use in combination with Checklist C-8-1)*
Checklist for Finished Die, SSM and Squeeze Casting Part Purchasing
No. Cost Effect
1
2
Most economical basis for production

Involves additional work which may
affect cost

3-4 Additional work which may increase cost
5 Most difficult surface to cast on a
production basis
Part #
K
L
M
N
This Finishing Checklist provides a convenient method for

assuring that important factors involved in the surface finishing
of cast parts are evaluated and clearly communicated between the
purchaser and the caster.
It should be used as a supplement to the essential dimensional
and alloy specifications detailed on part prints submitted for
quotation, since the listed factors directly affect the basis on which
the casting quotation is made. The checklist may be reproduced for
this purpose. Your caster will clarify any item requiring explanation.
This checklist provides a numbering system in which the lowest
numbered description for each requirement can be met at the
lowest production cost, as follows:
Casting Insert
1 No insert used in cast part

2 Inserts required, to be supplied by customer at 10% overage
3 Inserts required, to be supplied by caster
Parting Lines
1 Polishing not required

2 Polish only where marked on drawing
3 Polish all parting lines (except as noted)
Surface
Preparation
1 No buffing required
2 Mechanical (burnishing, tumbling, etc.)
3 Buff as indicated on drawing
Plating,
Anodizing
or Other
Special Finish
1 Protective Only Specify: ______________________________________
Painting
1 Heavy Paint, Protective Only Specify: ______________________________________
2 Decorative Paint Specify: ______________________________________

3 Severe Exposure Protection Specify: ______________________________________
2 Decorative Paint Specify: ______________________________________
3 Application requires base coat or special treatment: ___________________________________

Specify: ______________________________________
Environmental
1 Normal interior use only

2 Exposure to weather Specify: ______________________________________
3 Exposure to unusual chemistry Specify: ______________________________________
As-Cast
Surface
See NADCA
Guidelines
G-6-6
Special
Requirements
For special flash removal requirements, see Checklist C-8-1, items C & E
For special packaging/weight restrictions, see Checklist C-8-1, item J
1
2
3
4
Utility Grade surface imperfections acceptable, nondecorative coatings

Functional Grade slight, removable surface imperfections, heavier coatings
Commercial Grade removable imperfections
Consumer Grade no objectionable imperfections, as agreed upon, when viewed under
normal lighting conditions at ___________________ feet viewing distance
5 Superior Grade specified average surface finish value of ______________ microinches, per print
* The specification provisions and procedures listed in Section 7, Quality Assurance, should also be addressed.
Publisher grants permission to reproduce this checklist as part of a casting Request for Quotation or Production Specification.
8-16
Casting Examples
Aluminum
section
9-2
Pistol Frame
Rocker Arm
Right/Left Hand Bracket
Endbell
Engine Base Bracket
Water Passage
Heat Sink Front & Back
Chassis
B Pillar
Trimmer Deck Housing
RFU Enclosure
Impeller
Lower Crankcase
Differential Carrier
Beta Crankcase Right & Left
Scooter Monocoque Frame
Rear Wheel Drive Northstar Block Casting
Power Condition Module Chassis
MMC Brake Drum
AWD Clutch Housing
RWD Transmission
Magnesium
9-2
9-2
9-2
9-3
9-3
9-3
9-4
9-4
9-4
9-5
9-5
9-5
9-6
9-6
9-6
9-7
9-7
9-7
9-8
9-8
9-8
Zinc
Knot
Bracket
Faucet Handle
Connector
Kitchen Faucet Hub
Fuel Fitting
Reverse Valve Casket
Casket Arm
Display Frame Component
Outside Cover
Front Plate L-20
Connector Housing
Rearview Mirror Mount
Steering Wheel Ignition Lock Housing
Headlamp Visor
Camera Bracket
ZA (Zinc-Aluminum)
Tool Housing & Components
Transmission Shift Selector Tube
9-14
9-14
9-14
9-14
9-15
9-15
9-15
9-16
9-16
9-16
9-17
9-17
9-17
9-18
9-18
9-18
9-19
9-20
9-20
9-20
9-9
Frame
Head Node
Fishing Reel
Clutch Cover
Camera Assembly
Hand-Held Computer Housing
Gear Case Housing Assembly
Lock Housing
Fairing Support Bracket
Seat Back and Cushion
Lift Gate Inner Panel
Cross Car Beam for Instrument Panel
Oil Tank
SAWZALL Gear Case Assembly
9-9
9-9
9-9
9-10
9-10
9-10
9-11
9-11
9-11
9-12
9-12
9-12
9-13
9-13
9-1
Casting Examples
Aluminum
Part Name:
Pistol Frame
Application:
0.22 Caliber Pistol
Part Weight: 0.35 lbs.

Alloy:
A380
Comments:
Part was previously

machined from stock. This is
the first aluminum die casting
used by Smith & Wesson.
Customer:
Smith & Wesson
Aluminum
Part Name:
Rocker Arm
Application:
Honda Civic Engine

Alloy:
383
Comments:
Process improvements and

strict attention to detail
resulted in cost savings on
these high integrity, near
porosity-free parts. The parts
include a special wear
insert chip and meet very
tight specifications.
Customer:
Honda of America Mfg., Inc.
Aluminum
9-2
Part Name:
Right/Left Hand Bracket
Application:
BRP Skidoo
Part Weight:
0.75 lbs.
Alloy:
Aural-2
Comments:
Part was previously made

from low pressure permanent mold with extensive
machining. High vacuum
die casting created a heat
treatable and weldable
part for structural application, requiring minimal
machining. Overall piece
price reduction was on the
order of 40%.
Customer:
BRP Skidoo
Casting Examples
Aluminum
Part Name:
Endbell
Application:
Air Compressors

Alloy:
380
Comments:
Major tooling and process

improvements resulted in
scrap reduction, increased
cost savings, production and
quality. Completed cast units
highly competitive in the
market against lower entry
models produced using
stamped steel.
Customer:
Devilbiss Air Power

Company
Aluminum
Part Name:
Engine Base Bracket
Application:
Honda Accord Engine
Part Weight:
6.2 lbs.
Alloy:
ADC3SF jointly developed with

Honda, compatible with SF36,
Aural 2
Comments:
Replacing a previously stamped,

16 piece part, the new part is 27
in. long, thin-walled, with screw
bosses, eliminating the welding
operation and reduced weight by
43.6%.
Customer:
Honda
Aluminum
Part Name:
Water Passage
Application:
Honda Civic Engine

Alloy:
383
Comments:
The Water Pasage hose

mating surface is cast to
specifications allowing
the shipping of the part to
the customer without any
machining to the snout. This
tight tolerance allows a cost
savings to the customer.
The customer saves the cost
of machining for the snout,
which is estimated at a 23%
cost savings.
Customer:
Honda of America Mfg. Inc.
9-3
Casting Examples
Aluminum
Part Name:
Heat Sink Front & Back
Application:
Garmin G-1000
Flat Panel Flight Display

Alloy:
360
Comments:
Parts are assembled to

collect & disperse heat from
an LCD unit. Converted from
machined parts to die castings. Increased production
rate & reduced piece part
cost. First time use of aluminum heat sink for this type
of application. 360 alloy
was selected based on its
corrosion resistance which
protects the assembly from
oxidation & other corrosion resulting from frequent
atmospheric changes experienced by components used
in general aviation. Painting
or coatings are not required
& are ready for assembly
upon arrival at customer
location.
Customer:
Garmin International
Aluminum
Part Name:
Chassis
Application:
Human Transporter

Alloy:
380
Comments:
The casting is produced to

net shape and meets strict
specifications. True position
tolerances on critical dimensions were reduced resulting
in reductions in machining
and substantial cost savings.
Customer:
Segway
Aluminum
Part Name:
B Pillar
Application:
Automotive Structural
Support
9-4
Alloy:
380
Comments:
A new part cast for automobile body framing support

application. Yields weight
savings benefit over fabricated steel components.
Customer:
Casting Examples
Aluminum
Part Name:
Application:
Walk Behind Trimmer

Alloy:
380
Comments:
As compared to a previous
die casting design and tooling design, newly designed
tooling allowed for scrap
reduction (34%), cycle time
reduction (52 sec.) and
weight reduction (2 lbs.).
Customer:
Garden Way, Inc.
Aluminum
Part Name:
RFU Enclosure
Application:
Microwave Communications

Alloy:
413
Comments:
Formerly produced as an
investment casting. Provides
heat dissipation and electrical conductivity. Die casting
reduced lead time and
machining requirements.
Customer:
Harris Corporation,
Microwave Communications
Division
Aluminum
Part Name:
Impeller
Application:
Industrial/Commercial
Blower
Part Weight: 10.29 lbs

Alloy:
A380
Comments:
Impeller used in industrial

and commercial blowers.
The application of the die
cast part enabled the unit to
operate at higher speeds,
with less noise, while reducing the amount of secondary
machining.
Customer:
Ametek Rotron
9-5
Casting Examples
Aluminum
Part Name:
Lower Crankcase
Application:
Motorcycle

Alloy:
LM2 to JVM Specifications
Comments:
Redesign of original T120,

1959 Bonneville high performance version of Triumphs
650cc twin. Eliminated
costly secondary machining operations, additional
engine parts and fully
utilized the benefits of high
pressure die casting process.
Customer:
Triumph Motorcycles
Aluminum
Part Name:
Differential Carrier
Application:
Independent Rear
Suspension

Alloy:
ADC-12 -T6 Heat

Treatment
Comments:
Past generation was an iron

casting. First high volume
squeeze casting used in an
independent rear suspension axel carrier. Squeeze
casting decreased weight
by 22 pounds over cast iron
process.
Customer:
Visteon Corporation
Aluminum
Part Name:
Beta Crankcase
Right & Left
Application:
Motorcycle
9-6
Alloy:
383
Comments:
These net-shape, complex

castings were converted
from the permanent mold
process to meet stringent
specifications of improved
quality, pressure tightness,
cosmetic appearance,
higher volume and cost
reductions.
Customer:
Harley-Davidson
Casting Examples
Aluminum
Part Name:
Scooter Monocoque Frame
Application:
Honda Scooter Super Sport

Alloy:
JIS ADC12; 383 equivalent
Comments:
Previously fabricated from

steel sheet stamping and
pipes. Die casting provided
weight savings and cost
reduction.
Customer:
Honda R&D Co., Ltd.
Aluminum
Part Name:
Rear Wheel Drive Northstar

Block Casting
Application:
Rear Wheel Drive Northstar

Engine

Alloy:
A380
Comments:
Customer:
GM Powertrain
Aluminum
Part Name:
Power Conditioning
Module Chassis
Application:
Computer/Electronics
Part Weight:
2.3 lbs.
Alloy:
380
Comments:
Originally machined from

a roughly shaped ingot,
this chassis gained significant cost savings after
being converted to an
aluminum die casting.
Customer:
Novatel Wireless
Technologies, LTD
9-7
Casting Examples
Aluminum
Part Name:
Aluminum MMC Brake Drum
Application:
Commercial, Military, and

Special Vehicles
Part Weight:
38.5 lbs.
Alloy:
A356.2
Comments:
Originally produced in
cast iron. A unique horizontal squeeze cast process allowed a selectively
placed ceramic preform
to be infiltrated, creating
a selectively reinforced,
Metal Matrix Composite
(MMC) aluminum brake
drum. The new brake drum
weights at least 45% less.
Customer:
Century 3+ Inc.
Aluminum
Part Name:
Automotive AWD
Clutch Housing
Application:
Automotive
Part Weight:
2.4 lbs.
Alloy:
ADC12-T5
Comments:
Originally produced as a
multi-step forged steel housing, but this part was successfully convert this part
to an aluminum squeeze
casting. The new squeeze
cast design incorporated
33 spline teeth with 0.1
degree draft. A significant mass reduction was
obtained resulting in better
fuel efficiency and reduced
inertia for improved all
wheel drive engagement
response time.
Customer:
Borg Warner TTS, PTC
Aluminum
9-8
Part Name:
RWD Transmission
Application:
Automobile Industry
Part Weight:
37.4 lbs.
Alloy:
A380
Comments:
Utilizes a unique process,

involving 2 cast-in steel
tubes, which have to be
inserted in the ejector die
and maintain location.
Customer:
Chrysler
Casting Examples
Magnesium
Part Name:
Frame
Application:
Novatel Expedite Modem

Alloy:
AZ91D
Comments:
Converted from a plastic

part. The magnesium casting eliminated a plastic
part sandwiched between
two metal plates and held
together with self tapping
screws, resulting in cost savings to the customer.
Customer:
Novatel Wireless
Technologies, LTD
Magnesium
Part Name:
Head Node
Application:
Mountain Bike

Alloy:
AZ91D
Comments:
Originally designed as two

aluminum investment cast
parts, this unique die cast
mag design and application
yields a 30% weight savings, part and assembly cost
savings, better consistency
in impact and fatigue and
better performance.
Customer:
Cannondale
Magnesium
Part Name:
Fishing Reel
Application:
Ardent XS Fishing Reel
Part Weight: 31.3 grams

Alloy:
AZ91D
Comments:
Converted from plastic &

die cast aluminum components. Complex geometry
& varying wall thickness.
Tooling uses 3 slides to
form entire exterior of part.
Tight tolerance machining
of bores and surfaces for
mating components. 100%
made in USA (Components
& Assembly).
Customer:
Marsh Technologies, Inc.
9-9
Casting Examples
Magnesium
Part Name:
Clutch Cover
Application:
All Terrain Vehicle Clutch

Alloy:
AZ91D
Comments:
A conversion from aluminum

die casting to magnesium
die casting resulted in a
weight reduction of 45%
and a significant cost reduction by eliminating machining.
Customer:
Polaris Industries, ATV Div.
Magnesium
Part Name:
Camera Assembly
Application:
Digital Camera

Alloy:
AZ91D
Comments:
Originally designed as
aluminum investment cast
parts, the design complexity and required precision
mandated a transition to
magnesium die cast parts.
Customer:
Eastman Kodak
Magnesium
Part Name:
Hand-Held Computer
Housing
Application:
Hand-Held Computer
Part Weight: Over 0.5 lbs.
9-10
Alloy:
AZ91D
Comments:
Customer:
Telxon Corporation
Casting Examples
Magnesium
Part Name:
Gear Case Housing

Assembly
Application:
Automatic Power Pruner

Alloy:
AZ91D
Comments:
Magnesium was chosen

for its strength and low
weight for this application
over plastic and aluminum.
Bearing diameter tolerances
of 0.001 are required and
eliminate machining and
masking cost.
Customer:
Echo
Magnesium
Part Name:
Lock Housing
Application:
SUV Tilt Steering Column

Alloy:
AM60B
Comments:
This die casting controls the

tilt/telescoping features in
the steering column and
incorporates the ignition
switch, shift lever and
brake-shift interlock into one
casting. In addition to tight
dimensional control, the
higher elongation in AM60B
alloy provides good crash
energy management.
Customer:
Visteon/Ford
Magnesium
Part Name:
Fairing Support Bracket
Application:
Buell 1125R Superbike

Alloy:
AZ91D
Comments:
This bracket provides support for the motorcycles

instrument cluster, windshield/cowling, direction
signals and rearview mirror
with increase copacity and
a cost savings of aproximatly 26%.
Customer:
Buell Motercycle Co.
9-11
Casting Examples
Magnesium
Part Name:
Application:
Luxury Car Seat Back and

Cushion
Part Weight:
Alloy:
AM60B
Comments:
Customer:
Magnesium
Part Name:
Vehicle Lift Gate

Inner Panel
Application:
Automotive
Part Weight: 18 lbs.

Alloy:
AM60
Comments:
Replacing a stamped steel

assembly, this large die
cast magnesium lift gate
reduced weight, added
design flexibility and
reduced assembly time
through the integration of
various components. The
die cast lift gate is 54 x 52
inches.
Customer:
Ford Motor Co.
Magnesium
Part Name:
Cross Car Beam for

Instrument Panel
Application:
General Motors Medium

Duty Trucks
9-12
Alloy:
AM60B
Comments:
An example of maximizing
the die casting process,
machine and die to obtain
substantial cost savings. The
improvements resulted in
weight savings & cost reductions through decreased
material, downtime, and
elimination of machining/
repair.
Customer:
General Motors Truck
Casting Examples
Magnesium
Part Name:
Oil Tank
Application:
Snowmobile

Alloy:
AZ91D
Comments:
This magnesium oil tank

replaces one that was a
stamped aluminum and
brazed assembly. The case
is comprised of 3 separate
magnesium die castings. It is
lighter and more tunable than
the aluminum it replaces.
Customer:
Arctic Cat Inc.
Magnesium
Part Name:
SAWZALL Gear Case Assembly
Application:
Power Tool
Part Weight: .293 lbs.

Alloy:
AZ91D
Comments:
Met customer requirements

of eliminating machining and
reducing cost of similar aluminum
castings. Magnesium die casting
holds dimensional tolerances that
eliminate the need to machine.
Customer:
Milwaukee Electric Tool Co.
9-13
Casting Examples
Zinc
Part Name:
Knot
Application:
Marketing
Part Weight: 5.5 Grams

Alloy:
ZP5
Comments:
This items shape has never

been industrially manufactured and displays ingenious
part and tooling design.
Customer:
Nyrstar
Zinc
Part Name:
Bracket
Application:
Electronics Enclosure
Part Weight: 15.42 Grams

Alloy:
Zamak No. 3
Comments:
Converted from a machined

aluminum alloy resulting in
cost savings. The part is cast
to net-shape thereby totally
eliminating any machining.
Customer:
Zinc
Part Name:
Faucet Handle
Application:
Two Handle Lavatory Faucet
Part Weight: 119 Grams
9-14
Alloy:
Zamak No. 3
Comments:
Major cost savings were

achieved from tooling
changes, which eliminated
trimming, reduced polishing
the parting line and machining operations.
Customer:
Delta Faucet Company
Casting Examples
Zinc
Part Name:
Connector
Application:
TERA Connector
Part Weight: 0.4 oz.

Alloy:
Zamak No. 3
Comments:
Die casting offered superior

EMI shielding and mechanical integrity at a favorable
cost.
Customer:
Siemon Company
Zinc
Part Name:
Kitchen Faucet Hub
Application:
Pull-Out Faucet
Part Weight:
Alloy:
Zamak No. 3
Comments:
Customer:
Delta Faucet Company
Zinc
Part Name:
Fuel Fitting
Application:
Dragon Fly Cook Stove

Alloy:
Zamak No. 3
Comments:
Originally designed as an
assembly of three screwmachined components. Converting the component to die
cast Zamak 3 provided a
cost reduction and allowed
for the streamlining.
Customer:
Mountain Safety Research
9-15
Casting Examples
Zinc
Part Name:
Reverse Valve Casting
Application:
Snap-On Tools

Alloy:
Zamak No. 5
Comments:
Exceedingly complex,
high tolerance die casting
produced in high volumes
& requiring minimum
machining. Zinc die casting
selected over powder metallurgy, machining & metal
injection molding because
of lower production costs.
50 mils to 230 mils casting
thickness & a stepped hole
(to a final ID of 0.3000)
extending the length of the
cylinder with minimum draft.
Customer:
Vic Royal
Zinc
Part Name:
Casket Arm
Application:
Casket

Alloy:
Zamak No. 3
Comments:
This precisely cored zinc die

casting provides the right
amount of friction with the
hinge to allow the lift bar
to remain in the position it
was last set. Was a steel
stamping.
Customer:
Vic Royal
Zinc
Part Name:
Application:
Store Display Unit
9-16
Alloy:
Zamak No. 3
Comments:
Conversion from a steel

weldment to a die casting
resulted in substantial cost
savings. The casting is used
as the frame for a track running shoe display rack.
Customer:
CDC Marketing
Casting Examples
Zinc
Part Name:
Outside Cover
Application:
Power Lever Door Lock

Alloy:
Zamak No. 3
Comments:
Converted from a permanent mold casting, these die

cast parts offer thinner walls,
less prep for plating due to
the extraordinary surface
finish and cost savings
(39%).
Customer:
Mas-Hamilton Group
Zinc
Part Name:
Front Plate L-20
Application:
Telecommunications Extension Shelf

Alloy:
Za4Cu1
Comments:
New part for mounting optical and electrical cartridges.

Challenge of fill very thin
walls and narrow (0.2 mm)
flatness tolerance. Success
related to vacuum technology, die thermal conditioning and precision and sprue
runner design.
Customer:
ALCATEL ITALIA S.p.A.
Zinc
Part Name:
Connector Housing
Application:
Fiber Optic Transceiver

Alloy:
Zamak No. 2
Comments:
Previously produced from

multiple machined cast
metal or sheet metal fabricated parts, which lacked
precision for speedy assembly of components. Cost savings in material, production
methods and labor were
achieved with the conversion to die casting.
Customer:
Agilent Technologies
9-17
Casting Examples
Zinc
Part Name:
Application:
Windshild-to-mirror head
transition housing
Part Weight:
4.1 oz.
Alloy:
Zamak No. 5
Comments:
The part was designed

around the mirror mounts
humidity sensor for the
smallest possible footprint.
Customer:
Gentex Corporation
Zinc
Part Name:
Steering Wheel Ignition

and Lock Housing
Application:
Automotive
Part Weight:
13.9 oz
Alloy:
Zamak #5
Comments:
The ignition and lock housing is a safety-critical component of the automotive

steering column. It keeps
the steering wheel locked
until the car is ready to
start and drive.
Customer:
Valeo Sisitemas
Electronics, SA de CV
Zinc
9-18
Part Name:
Headlamp Visor
Application:
Harley-Davidson Motorcycle
Part Weight:
2.78 lbs.
Alloy
ZA8
Comments:
Combined two parts

into one to reduce cost
and part numbers. As
the center point of the
integrated motorcycle
handlebar assembly it
needs to be functional and
aesthetic. Carefully controlled process produces
a surface finish conducive
for a highly cosmetic
chrome plate finish.
Customer:
Harley-Davidson
Casting Examples
Zinc
Part Name:
Bracket, Camera, ASIC
Application:
Infrared Interactive
Whiteboard
Part Weight:
0.065 oz.
Alloy
Zamak #3
Comments:
This zinc die casting

replaces an ABS plastic
part. It improves the
product durability and
performance. The casting
is used to hold an infrared
camera ridigly in place on
an interactive whiteboard.
This whiteboard connects to a computer and
employs infrared light to
locate all interactions with
the whiteboard.
Customer
SMART Technologies
9-19
Casting Examples
ZA (Zinc-Aluminum)
Part Name:
Tool Housing
& Components
Application:
Air-Powered Hand Tool
Part Weight:
Alloy:
ZA-8 and ZA-27
Comments:
The components for this air

ratchet tool consist of two
die cast ZA-27 split halves
incorporating as-cast grip
surface embossing, logos and
identification and a one-piece
ZA-8 air manifold that does
not require machining. ZA
alloys allowed wall thicknesses of 0.060 inch for the
handles and enhanced sound
suppression for quieter operation. Previously an assembly
of a machined steel head and
a cast aluminum handle housing that required extensive
machining was used.
Customer:
Snap-On
ZA (Zinc-Aluminum)
Part Name:
Transmission Shift Selector

Tube Unit
Application:
Passenger Car & Light Truck
Part Weight: 1.1 lb.
9-20
Alloy:
ZA-8
Comments:
This single die casting

replaced a four piece
assembly and resulted in an
estimated 50% cost savings.
Customer:
Index
Conversion Charts
A
Acceptance of Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Alloy Cross Reference Designations
. . . . . .
3-2, 3-42
Alternate Surface Textures . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Aluminum

Alloy Characteristics
Alloy Chemical Composition . . . . . . . . . . . . . . . . 3-5
Alloy Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
. . . . . . . . . . . . . . . . . . . . . . . . .
3-7
Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Casting Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Composites Characteristics
Composites Chemical Composition . . . . . . . 3-13
Composites Properties
Metal Matrix Composites
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
3-15
3-14
3-12
Angularity Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13

Available Finishes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-11
AWD Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
B
B Pillar
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5
Beta Crankcase Right & Left . . . . . . . . . . . . . . . . . . . . . . . . 9-7
5-29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coordinate Measurements to Position

Location Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Copper

Alloy Chemical Composition . . . . . . . . . . . . . . . 3-17
Alloy Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
. . . . . . . . . . . . . . . . . . . . . . . .
3-19
Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Core Slide Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Cored Holes
As-Cast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-31

for Cut Threads . . . . . . . . . . . . . . . . . . . 4A-34, 4A-35
for Formed Threads . . . . . . . . . . . . . . . . . . . . . . . . 4A-36
for Pipe Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-38
Corners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Credit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crimping, Staking, Bending and Forming
8-7, 8-9
. . . .
4B-10
Cross

Car Beam for Instrument Panel
Reference of Alloy Designations

and Alloy Compositions . . . . . . . . . . . . . . . . . . . . 3-42
. . . . . . . . . . . .
9-12
Cylindricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
D
C
Camera Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Database Guidelines . . . . . . . . . . . . . . . . . . . . . . . 2-16, 8-13

9-10
Datum
Camera Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Datum Feature vs. Datum Plane
Cancellations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Datum Plane vs. Datum Axis
Casket Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Reference Framework . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cast Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-39
Target Sizes & Locations . . . . . . . . . . . . . . . . . . . . . 5-6
Castable Zinc Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-11
Defects
Cast-in Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9, 8-11
External
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8
Casting Features
Internal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7
. . . . . . . . . . . . .
5-5
. . . . . . . . . . . . . . . . .
5-5
Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Changes or Cancellation
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Design Considerations
for Miniature Die Castings . . . . . . . . . . . . . . . . . . . . . . . . 4B-7
Circularity (Roundness)
Die
. . . . . . . . . . . . . . . . . . . . . . . . . .
8-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Clutch Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
and Cavity Materials
Combining Functions
4B-9
Cast Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Concentricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-17, 5-13
Casting Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Cavity Insert Materials . . . . . . . . . . . . . . . . . . . . . . 2-10
Connector Housing
Considerations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-17
Controlling Die Performance . . . . . . . . . . . . . . . . . . . . . 2-11
Life
........................
2-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
2-7
2-16, 2-19, 8-5
10-1
Index
Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Gage (ing)
Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
GD&T
Repair & Replacement
advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Retention Period and Removal . . . . . . . . . . . . . . 8-7
Steel Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Gear Case Housing Assembly . . . . . . . . . . . . . . . . . . . 9-11
. . . . . . . . . . . . . . . . . . . . . . .
8-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14,7-10, 8-7
when to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Gears
9-16
General Database Guidelines . . . . . . . . . . . . . . . . . . . . 8-3
Draft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-7
Geometric Symbols and Terms . . . . . . . . . . . . . . . . . . . . 5-8
Tolerances
Drawings
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B-10
4A-21, 4A-23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9
H
Hand-Held Computer Housing . . . . . . . . . . . . . . . . . . . 9-10
Head Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Ejector Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9, 6-6

Elevated Temperature Properties
. . . . . . . . . . . . . . . .
Heat Sink Front & Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
3-34
Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Engine Base Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Engineering
Inherited Tooling
Consultation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insert Die Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-10
Team . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Inserts, Cast-in-Place
Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Insurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Extended Die Life
2-12
Inventory Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Fairing Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Kitchen Faucet Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Faucet Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Knot
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feature Control Frame

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-14
5-6
and Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8
Finishing Specifications
...............................
Fillets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
L
Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8-13, 8-15
Large Casting Considerations . . . . . . . . . . . . . . . . . . 4A-42
First Article Inspection Requirements (FAIR) . . . . 7-10
Least Material Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
First-Piece Acceptance
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7
Lift Gate Inner Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-9
Limitations on Inspection Procedures . . . . . . . . . . . . 8-10
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Limitations on Warranties . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Flash Removal
6-7
Linear Dimensions Tolerances . . . . . . . . . . . . 4A-7, 4A-8
4A-29, 4A-30
Location Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fishing Reel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flatness Tolerances
. . . . . . . . . . . . . . . . . . . .
Form Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Lock Housing
Frame
Lower Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Plate L-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

Fuel Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
10-2
2-15
9-11
Index
Payment Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
M
. . . . . . . . . . . . . . . . . . .
4A-40
Pin
Flash
Magnesium
3-23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Alloy Chemical Composition . . . . . . . . . . . . . . . 3-21
Pistol Frame
Alloy Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Porosity
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal
Material Conditions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8
Control: Gating, Venting, Vacuum
9-2
7-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Casting Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
6-6
.........
2-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-14
Parting-Line
7-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Material Condition . . . . . . . . . . . . . . . . . . . . . 5-8
Position Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Measurement
Position Tolerance to-from

Coordinate Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
7-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metal

Extension (Flash) Removal . . . . . . . . . . . . . . . . . . . 6-7
Market Pricing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Miniature Die Casting

Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4
Machines
4B-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminology
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MMC Brake Drum
4B-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-8
Moving Die Component

Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-11, 4A-12
PPM Levels
. . . . . . . . . . . . . . . . . . . . . . . . . .
2-17
Pressure
Tightness

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tight Castings
Oil Heating Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

..............................................
9-13
Operating Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Orientation Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10
Outside Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
P
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Part Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B-9
Parting Line
Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-19, 4A-20
Tolerances
. . . . . . . . . . . . . . . . . . . . . . . . . .
4A-9, 4A-10
Cover & Ejector Die Halves . . . . . . . . . . . . . . . . . 2-8
and Ejector Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8
Patent Obligations
6-3
7-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Price (ing)
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Metal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8, 8-11
Primary, Secondary, Tertiary

Features & Datums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Capabilities with
Product Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Ornamentation
9-8
7-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capability
Oil Tank
. . . . . . . . . . . . . . . . .
Process
N
New Die-Inherited Die
Specifications, Checklist
Power Condition Module Chassis
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Quality
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
Production
Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Part Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
Part Orders
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications
Tooling
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Profile Tolerances
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8
8-4
5-14
Property Comparison (Alloy Data) . . . . . . . . . . . . . . 3-38

Prototype Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Purchased Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
10
8-12
10-3
Index
7-11
. . . . . . . . . . . . . . . . . . . . . . . .
Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Steering Wheel Ignition Lock Housing . . . . . . . . . . 9-18
Quick Guide to Alloy Family Selection . . . . . . . . . 3-33
Straightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Quotations
Surface
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11
Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8

Finish, As-Cast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Symmetry Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Rear
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Wheel Drive Block Casting
. . . . . . . . . . . . . . . . . .
9-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
Taxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
9-18
Taylor Principle (Envelope Principal) . . . . . . . . . . . . . . 5-7
5-10
Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Reorders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Thermal Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Reverse Valve Casket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-10
RFU Enclosure
9-5
Cast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-39
4B-7, 6-5
Tool Housing & Components . . . . . . . . . . . . . . . . . . . . . 9-19
Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Transmission Shift Selector Tube . . . . . . . . . . . . . . . . . 9-19
Runout Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Trim Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Rear Axle Thrust Rod
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Regardless of Feature Size
Ribs
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5
Typical Design and Tolerance Data . . . . . . . . . . . . . 4B-3
S
Scooter Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
. . . . . . . . . . . . . . . . . . . . . . . . . . .
9-12
Secondary Machining Preplanning . . . . . . . . . . . . . 2-14
Uniform Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8
Selecting
Unit Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Aluminum Alloys
Aluminum Composites
an Alloy Family
Copper Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9
Magnesium Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Zinc and Zinc-Aluminum Alloys . . . . . . . . . . . . 3-26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.......................
3-4
3-32
..............................
3-12
Shrinkage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B-7
Side Cores
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B-9
Vacuum
2-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W
Warranties
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12
Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
limitations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skin
Water Passage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPC Procedures
4B-10
7-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight Reduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13
9-3
4B-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Checklists
10-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2
Specifying Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Zinc
SSM & Squeeze Cast Part Design . . . . . . . . . . . . . . 4A-6
Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Standard
and Precision Tolerances
vs. Precision Tolerances . . . . . . . . . . . . . . . . . . . . . . . 7-3
. . . . . . . . . . . . . . . . . .
Casting Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
4A-3
Index
Zinc and Zinc-Aluminum
Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Characteristics

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-29
Chemical Composition . . . . . . . . . . . . . . . . . . . . . . 3-27
Properties
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-28
Casting Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
High Fluidity (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
10
10-5
Index
This page left blank intentionally.
10-6
Glossary
This glossary of terms is presented to
aid the product designer and specifier in
communicating with the custom die caster
during product development and production.
It includes definitions involved in product
prototyping, the design and construction of
the die casting die and trim die, die casting
production and post-casting machining and
surface finishing operations.
Abrasive blasting
A process for cleaning or finishing by which
abrasive particles are directed at high velocity
against a casting or work piece.
Alloy, primary
Any die casting alloy whose major constituent
has been refined directly from ore, not recycled
scrap metal.
Alloy, secondary
Any die casting alloy whose major constituent is obtained from recycled scrap metal.
Nearly 95% of die castings provided in North
America are made from secondary alloys.
Alloy, standard
Any die casting alloy that has been assigned an
ASTM designation.
Acid pickle
A method to remove oxides and other contaminants from metal surfaces.
Aging
A change in the metallurgical structure of an
alloy occurring over a period of time following
casting, which affects the properties and
dimensions. Heating accelerates aging.
Aging, artificial
A low temperature heat treatment meant to
accelerate aging, generally applied to increase
strength and/or to stabilize properties.
Aging, natural
Aging that occurs at room temperature.
Alloy
A substance having metallic properties and
composed of two or more chemical elements,
of which at least one is metal. Alloy properties are usually different from those of the
alloying elements.
Alloying
The process of making a die casting alloy from
its various constituents. The process usually
consists of melting the major constituent and
adding the others to the bath where they then
dissolve. The molten metal is then cleaned of
contamination by fluxing.
Amortization
A financial method to defer tooling cost and
include the tooling cost with casting production
on a prorated basis. For example, if tooling life
is agreed to be 100,000 acceptable castings and
the tooling cost is $100,000, the prorated cost is
$1.00 per each acceptable casting shipped, and
invoiced at shipment.
Anode
The electrode in a plating bath at which metal
ions are formed, negative ions are discharged
or other oxidizing reactions occur.
Anodic metal
Any metal that tends to dissolve, corrode or
oxidize in preference to another metal when
the metals are connected electrically in the
presence of an electrolyte.
10
10-7
Glossary
Anodizing
To subject a metal to electrolytic action as the
anode of a cell in order to coat with a protective or decorative film.
ANSI
Ball burnishing
The smoothing of surfaces by means of
tumbling parts in the presence of hardened
steel balls, without abrasives.
Barrel burnishing
American National Standards Institute.
AQL
Acceptable Quality Level, as agreed upon for
the fulfillment of production orders.
As-Cast
Condition of a casting that has not been given
a thermal treatment subsequent to casting.
This is also termed as the F temper.
ASQ
American Society for Quality.
ASTM
American Society for Testing and Materials.
The smoothing of surfaces by means of tumbling

a part in rotating barrels in the presence of
metallic or ceramic shot, without abrasives.
Barrel plating
Plating in which a part is processed in bulk in
a rotating container.
BHN
Brinell Hardness Number, scale used to
indicate hardness.
Biscuit
Excess metal left at the end of the injection
cylinder of a cold-chamber die casting
machine, formed at the end of the plunger
stroke. Also called a slug.
Black chromium
Atmospheric corrosion
Surface corrosion caused by exposure in the
environment to gasses or liquids that attack
the metal.
Bailment
The voluntary transfer of property, such as
dies, fixtures, gages, etc., in trust by the Bailor
(customer) to the Bailee (vendor). This can be
codified with a Bailment Agreement.
Nonreflective, black chromium coating

electrodeposited from a sulfate-free bath.
Black nickel
Nonreflective, decorative, black nickel coating
having little protective value, produced by
electroplating or simple immersion.
Blister
A surface defect or eruption caused by
expansion of gas, usually as a result of heating
trapped gas within the casting, or under metal
which has been plated on the casting.
10-8
Glossary
Blow holes
Cpk
Voids or holes in a casting that may occur due

to entrapped air or shrinkage during solidification of heavy sections.
Bright finish
A finish with a uniform nondirectional smooth
surface of high specular reflectance.
Bright nickel
Decorative nickel plate that is deposited in the
fully bright condition.
Bright plating
A process that produces an electrodeposit
having a high degree of specular reflectance
in the as-plated condition. Abrasive particles
are applied in liquid suspension, paste or
grease stick form.
Buffing
Smoothing a surface with a rotating flexible
wheel, to the surface of which fine abrasive
particles are applied in liquid suspension, paste
or grease-stick form.
Burnishing
Total process capability. A production process

capability index of both a process dispersion
and its central tendancy, taking into account the
spread of the distribution and where the distribution is in regard to a specification midpoint.
CQI
Continuous Quality Improvement, an
approach to quality management that builds
upon traditional quality assurance methods by
emphasizing the organization and systems. It
focuses on process rather than the individual;
recognizes both internal and external customers; and, promotes the need for objective data
to analyze and improve processes.
Cadmium plate
A coating of cadmium metal applied to an
aluminum or steel substrate for corrosion
protection or improved solderability. Cadmium
plate on zinc die castings requires an intermediate barrier layer of nickel.
Cass test
(Copper accelerated salt spray) An accelerated
corrosion test for electroplated substrates
(ASTM 368-68).
Castability
The smoothing and polishing of a metal

surface by rubbing or tumbling in the presence
of metallic or ceramic balls and in the absence
of abrasives.
Butyrates
The relative ease with which an alloy can be

cast; includes the relative ease with which it
flows and fills out a die/mould cavity, and its
relative resistance to hot cracking and tearing.
Casting rate
Organic coatings based on butyric acid

derivatives having excellent initial color and
good resistance to weathering.
The average number of shots that can be cast

during one hour of steady running.
10
Cp
Capability index.
10-9
Glossary
Casting section thickness
The wall thickness of the casting. Since the
casting may not have a uniform thickness, the
section thickness may be specified at a specific
place on the casting. Also, it is sometimes
useful to use the average, minimum or typical
wall thickness to describe a casting.
Casting yield
The weight of casting or castings divided by
the total weight of metal injected into the die,
expressed as a percent.
Casting cycle
The total number of events required to make
each casting. For die castings, the casting
cycle generally consists of solidification time,
machine movement and sequencing time and
the operators manual movements.
Casting drawing
The engineering drawing that defines the
size, shape and tolerances of the casting. This
is a detailed drawing of the casting only and
not an assembly of the product in which the
casting is included.
Casting, functional
A die casting that serves a structural or mechanical purpose only. It has no decorative value.
Casting thickness
See Casting section thickness.
Casting, thin wall

A term used to define a casting which has
the minimum wall thickness to satisfy its
service function.
10-10
Casting volume
The total cubic units (i.e. cu. in. or cu. mm) of
cast metal in the casting.
Cathode
The electrode in electroplating at which
metallic ions are discharged, negative ions are
formed or other reducing actions occur.
Cathode robber
An auxiliary cathode so placed as to divert
electrical current to itself from portions of the
articles being plated which would otherwise
receive too high a current density.
Cathodic metal
Any metal that does not tend to dissolve, corrode or oxidize in preference to another metal
when the metals are connected electrically in
the presence of an electrolyte.
Cavity
The recess in the die in which the casting
is formed.
Cavity block
The portion of the die casting die into which
most, if not all, the cavity is formed. There are
usually at least two cavity blocks in each die set.
Cavity fill time

That period of time required to fill the cavity with
metal after the metal begins to enter the cavity.
Center line shrinkage

Shrinkage or porosity occurring along the
central thermal plane or axis of a cast part.
Glossary
Charpy
Clamping force
Name of an impact test in which the specimen, forming a simple beam, is struck by a
hammer while resting against anvil supports
spaced 40 mm apart.
Actual force applied by a die casting machine

to a die clamp to keep the die closed. This may
be less than the clamping capacity of the die
casting machine.
Cold chamber
Checking
See Fatigue, thermal.
Chemical cleaning
The removal of foreign material from a surface
by means of immersion or spraying without
the use of current.
The molten metal chamber of a cold-chamber,

die casting machine. This is a hardened tube (shot
sleeve) through which the shot plunger moves to
inject the molten metal into die. The cold chamber
and plunger combine to form a metal pump. It is
called the cold chamber because it is cold relative
to the metal put into it.
Cold forming
Chromate
A conversion coating consisting of trivalent
and hexavalent chromium compounds.
Chromating
The application of a chromate coating.
Chrome pickle
A chemical treatment for magnesium in nitric
acid, sodium dichromate solution. The treatment
gives some protection against corrosion by
producing a film that is also a base for paint.
Chromium plate
A coating of electrodeposited chromium metal
which affords superior resistance to tarnishing
and abrasion.
Clamping capacity
The force a die casting machine is capable of
applying against the platen to hold the die
closed during metal injection.
Bending of a die casting without the application of heat to achieve a desired shape that is
different than that as cast. Cold forming is
frequently used to hold an assembled part to
the die casting.
Cold shut
A lapping that sometimes occurs where metal
fronts join during the formation of solidified
metal that sometimes occurs in the formation
of die castings which constitutes an imperfection on or near the surface of the casting.
Cold-Chamber machine
A die casting machine designed so that the
metal chamber and plunger are not continually
immersed in molten metal.
Color anodize
An anodic coating that is dyed before sealing
with an organic or inorganic coloring material.
10
10-11
Glossary
Coloring
Cooling channel
The production of desired colors on metal

surfaces by appropriate chemical or electrochemical action, or light buffing of metal
surfaces for the purpose of producing a high
luster; also called Color Buffing.
Combination die
A die with two or more different cavities
each producing a different part, also called a
family die.
Composite plate
An electrodeposit consisting of two or more
layers of metal deposited successively.
Compressive yield strength

The maximum stress that a metal, subjected to
compression, can withstand without a predefined
amount of yield (normally 0.2% for die castings).
Contraction
The linear change typically occurring in metals
and alloys on cooling to room temperature.
Contraction Factor
A factor used to multiply casting dimensions to obtain casting die dimensions. It
accommodates differences in Coefficients of
Thermal Expansion of the die steel and alloy,
and die operating temperatures.
Conversion coating
A coating produced by chemical or electrochemical treatment of a metallic surface that forms a
superficial layer containing a compound of the
metal; example: chromate coatings on zinc and
cadmium, oxide coating on steel.
10-12
A tube or passage in a die casting die through

which a coolant (typically water, oil or air) is
forced to cool the die.
Copper plate
A coating of copper deposited by electrolytic
or electroless plating methods. Copper electroplated from a cyanide solution is generally used
as the initial layer in plating zinc die castings.
Acid copper is used as a leveling deposit under
nickel-chromium plate.
Core
A part of a die casting die that forms an internal
feature of the casting (usually a feature with
considerable dimensional fidelity) and is a
separate piece from the cavity block. A core may
be fixed in a stationary position relative to the
cavity block or may be actuated through some
movement each time the die is opened.
Core pin
A core, usually of circular section. Core pins are
hot work tool steel pins, usually H-13, used for
a cored hole in a die casting and may be fixed or
movable. A core is made from a core pin.
Core plate
The plate to which the cores are attached and
which actuates them.
Core slide
Any moving core.
Core, fixed
A core that, as the die opens and closes, does
not move relative to the cavity block into
which it is mounted.
Glossary
Core, moving
A core that must move through some travel as
the die opens or immediately after the die has
opened, to allow the unrestricted ejection of
the casting.
Creep strength
The constant nominal stress that will cause a
specified amount of creep in a given time at a
constant temperature.
Current shield
Corrodkote
An accelerated corrosion test for electroplated
substrates (ASTM 380-65).
A nonconducting medium for altering the

current distribution on an anode or cathode.
Damping
Corrosion
Degradation of a metal by chemical or electrochemical reaction with its environment.
Corrosion endurance
Resistance to corrosion as a function of time.
Ability of material to dampen vibration in

components and thus lower noise levels.
DOE
Design of Experiments
Deburring
Cover gas
A mixture consisting of sulfur hexafloride,
carbon dioxide and air, used to protect and
minimize oxide formation on the surface of
molten magnesium.
Cover; cover die

The stationary half of a die casting die.
Covering power
The ability of a plating solution, under a
specified set of plating conditions, to deposit
metal on the surfaces or recesses of a part, or
in deep holes.
Creep
Plastic deformation of metals held for long
periods under stresses less than the normal
yield strength.
The removal of burrs, sharp edges or fins by

mechanical, chemical, electrochemical or
electrical discharge means.
Decorative finish
A plated, painted or treated surface having
aesthetic qualities and the ability to maintain
those qualities in service.
Defect
Imperfections in a cast part - such as pores,
inclusions, cracks, cold shuts, laps or the like.
Deflection
The bending or twisting of a die casting or a
tool when a load is imposed on it. Deflection
is normally used to describe elastic strain (i.e.,
the item will return to its original shape when
the load is removed) rather than permanent
(plastic) deformation.
10
10-13
Glossary
Deformation, plastic
Bending or twisting of a die casting or a tool
by a load that is beyond its elastic limits,
and the casting or tool does not return to its
original shape when the load is removed.
Degasifier
A substance that can be added to molten metal
to remove soluble gases that might otherwise be
entrapped in the metal during solidification.
Degassing
(1) A chemical reaction resulting to remove
gases from the metal. Inert gases are often
used in this operation. (2) A fluxing procedure
used for aluminum alloys in which nitrogen,
chlorine, chlorine and nitrogen and chlorine
and argon are bubbled up through the metal
to remove dissolved hydrogen gases and oxides
from the alloy. See also flux.
Degreasing
The removal of grease and oils from a surface.
Dendrite
A crystal that has a tree-like branching pattern
most evident in cast metals slowly cooled
through the solidification range.
Deoxidizing
(1) The removal of oxygen from molten metals
through the use of a suitable deoxydizer. (2)
Sometimes refers to the removal of undesirable
elements other than oxygen through the
introduction of elements or compounds that
readily react with them. (3) In metal finishing,
the removal of oxide films from metal surfaces
by chemical or electrochemical reaction.
10-14
Dichromate process
A chemical treatment for aluminum, magnesium and zinc alloys in a boiling dichromate
solution, resulting in a surface film that
resists corrosion.
Die
A metal block used in the die casting process,
incorporating the cavity or cavities that form
the component, the molten metal distribution
system and means for cooling and ejecting
the casting.
Die block
The large block of steel that forms the base
for one half of a die casting die. All other
components of the die are attached to or
mounted on the die block.
Die cast skin

The metal on the surface of a die casting, to
a depth of approximately 0.020 in. (0.8 mm),
characterized by fine grain structure and
freedom from porosity.
Die casting
A process in which molten metal is injected
at high velocity and pressure into a mold (die)
cavity.
Die halves
A die casting die is made in two parts, the
cover and the ejector. These are called the
halves of the die.
Die insert
A removable liner or part of a die body.
Glossary
Die life
Die weight
(1) The number of usable castings that can be

made from a die before it must be replaced
or extensively repaired. (2) The distance,
in inches or millimeters, measured in the
direction of the trimming action that a die
cast trimming die is fitted to the casting.
As trim dies are repeatedly sharpened, die
life distance is reduced. When the die life is
completely sharpened off, the die steels must
be replaced.
The mass (weight) of a die. The weight is

stamped on the die so individuals handling it
can select the proper lifting equipment.
Die, miniature
Die casting dies for making die castings that
weigh less than two ounces (55 grams) are
usually considered to be miniature die casting
dies.
Die release
Die coating to improve casting surface quality
and facilitate removal from die.
Die or steel safe

A technique employed in close-tolerance die
casting in which exterior surfaces of the casting are deliberately made slightly under size,
and interior surfaces slightly over size. After
a trial casting run, all dimensions are brought
within specified tolerances. This technique
ensures that all final die modifications, no
matter how slight, are made by removing,
rather than adding, metal.
Die, multiple-cavity
A die having more than one casting cavity.
Die, single cavity

A die casting die that has only one cavity.
Dimension, critical
A dimension on a part that must be held
within the specified tolerance for the part
to function in its application. A noncritical
tolerance is specified for weight saving or for
manufacturing economy, and is not essential
for the products function.
Die temperature
A die casting die has a very complex pattern
of temperatures across its parting surface and
through its thickness. The expression die
temperatures is usually used to mean die
surface temperatures.
Die temperature control

The use of thermocouples in the die casting
die to regulate flow rate of the cooling fluid
through the die, keeping die temperature
within preset range.
Dimension, linear
Any dimension to features of the die casting
that are formed in the same die component
(half). Any straight line dimension on a part
of die print.
Dimension, nominal
The size of the dimension to which the tolerance is applied. For example, if a dimension is
2.00 0.02, the 2.00 is the nominal dimension
and the 0.02 is the tolerance.
10
10-15
Glossary
Dimension, parting line
A dimension on a casting, or in a die casting
die cavity, that is parallel to the direction of
die pull and crosses the die parting line.
Dimensional stability
Ability of an alloy to retain its size and shape
unchanged with time.
Discontinuity
Any interruption in the normal physical
structure or configuration of a part, such as
cracks, laps, seams, inclusions or porosity. A
discontinuity may or may not affect the utility
of the part.
Draft
The taper given to cores and other parts of the
die cavity to permit easy removal of the casting.
Drag-Out
The solution that adheres to the objects
removed from cleaning and plating baths.
Dross
Metal oxides in or on the surface of molten metal.
Dull finish
A finish virtually lacking both diffuse and
specular reflectance.
Dolomite
A mineral made up of calcium and magnesium
carbonate.
Eject
To push the solidified casting out of the cavity
of the die casting die.
Double-Layer nickel
An electroplated, double-layer nickel coating,
of which the bottom layer is semi-bright nickel
containing less that 0.005% sulfur and the top
layer is bright nickel containing more than
0.04% sulfur; the thickness of the bottom layer
is not less than 60% of the total nickel thickness,
except on steel where it is not less than 75%.
Dowel pin
A guide to ensure registry between two
die sections.
Draft allowance
The maximum angle of the draft that is
allowed by the castings specification.
10-16
Ejection, accelerated
A system, usually within the die casting die,
that causes selected ejector pins to move faster
and further than the others during the final
portion of the ejection travel. Also called
Secondary Ejection.
Ejector marks
Marks left on castings by ejector pins, frequently including a light collar of flash formed
around the ejector pin.
Ejector pin
A pin actuated to force the casting out of the
die cavity and off the cores.
Glossary
Ejector plate
Plate to which the ejector pins are attached
and which actuates them.
Ejector; ejector die

The movable half of a die casting die containing the ejector pins.
Electrolyte
Entrained air
Air or other gases that are mixed with the
flowing molten metal as the die cavity is filling.
Epoxies
Organic coatings applied to parts, having
superior corrosion resistance and adhesion.
Erosion
A substance, usually liquid, in which the conduction of electricity is accompanied by chemical

decomposition. An electrolyte is one of the factors
required for electrolytic corrosion to occur.
Electromotive series
A list of elements arranged according to their
standard electrode potential.
Electroplate
An adherent metallic coating applied by
electrodeposition on a substrate for the
purpose of improving the surface properties.
Electropolishing
The improvement in surface finish of a metal
effected by making it anodic in an appropriate
solution.
Elongation
Amount of permanent extension in the vicinity
of the fracture in a tensile test, usually expressed
as a percentage of original gage length.
Engraved finishes
Designs etched on die cavity surfaces by
chemical dissolution to produce specified
patterns in the as-cast part.
A damaged condition in the die cavity or die

runners caused by the impingement of the
molten metal during injection.
Expansion, thermal coefficient of

A numerical value of the unit change in length
of a substance with each degree of temperature
change. These values are arrived at by experimentation and are tabulated in reference books.
Extractor
In die casting, a mechanical apparatus that
enters the space between the two halves of
the opened die casting die, grips the cast shot,
pulls it free from the ejector pins and removes
it from the die space.
FAIR
First Article Inspection Report
FMEA
Failure Mode and Effect Analysis
FEA
See Finite element analysis.
10
10-17
Glossary
Fatigue
Finish machining
The phenomenon leading to fracture under

repeated or fluctuating stresses that have a
maximum value less than the tensile strength
of the material.
Fatigue, thermal
The cracking (or crazing) of the die cast die
cavity surface. This is caused by the expansion
and contraction of the cavity surface which
happens every time molten metal is injected
into the die.
Feedback
A process control principle in which information about the actual performance of a
machine, tool, die or process is inputted into
the machine control system for the purpose of
possible machine adjustments to correct any
inaccurate variable.
Feeding
Ferric nitrate treatment

Process for producing a bright, corrosion-resistant finish on magnesium.
Curved juncture of two surfaces; e.g., walls

that would otherwise meet at a sharp corner.
10-18
The smoothness of the surface of a die casting

or a die casting die cavity. The finish quality of a
cavity surface may be specified as the grit size to
be used in the final polishing, microinch RMS
value or SPI/SPE finish standard number.
Finite element analysis

A numerical simulation procedure that can
be used to obtain solutions to a large class of
engineering problems including stress analysis,
fluid flow, heat transfer and many more.
The preciseness or accuracy with which two

parts must be fitted together. The clearance or
interference between two interconnected parts.
When a die casting must be made to unusually
close tolerances to achieve a specified fit, it
may impose a higher cost on its manufacture.
Fixture
Any apparatus that holds a part, such as a
die casting, firmly in a predetermined position while secondary operations are being
performed on the part.
Fillet
See Flash.
Finish
Fit
The process of supplying molten metal to the

die cavity to compensate for volume shrinkage
while the cast part is solidifying.
Fin
(1) The last machining operation on the

cavity of a die casting die before the hand
work (benching or polishing) is started. (2)
Machining operations on a part that has been
die cast to bring the part to final specified
tolerances, where die casting to net-shape was
not economically feasible.
Flash (metal extension)

The thin web or fin of metal on a casting
occurring at die partings, air vents, and around
movable cores. The excess metal is due to the
working pressure and operating clearances in
the die.
Glossary
Flash, clearance
In die casting dies, spaces deliberately provided between parts of the die for the formation of flash. In trim dies and other secondary
tooling, spaces provided for the positioning of
the casting flash.
Flash, trimmed
The excess material that has been trimmed
from a die casting that will be remelted and
used over again.
Flux
A substance such as halide salts used to
protect and minimize oxide formation on the
surface of molten metal. Also used to refine
scrap metals.
Form
The shape of a die casting.
Forming, cold
Flow lines
Marks appearing on the surface of a casting
that indicates the manner of metal flow.
Flow pattern
The pattern with which the molten metal
progressively fills the cavity of a die casting die.
Flow rate
The volume per unit time of molten metal
entering a cavity in a die casting die. Flow
rates are expressed in cubic inches or cubic
millimeters per second.
Fluid bed coating

A process in which the metal to be coated is
heated and inserted into the powdered resin
which is fluidized in air.
Any of several processes in which a die casting

is reshaped by a tool or fixture, usually in a
power press, without the application of heat.
Spinning, which generates some localized
heat, is still considered a cold forming
operation. Heat staking, which utilizes heated
punches, is not a cold forming operation.
Fracture test
Breaking a specimen and examining the
fractured surfaces to determine such things
as composition, grain size, soundness or
presence of defects.
Freezing range
That temperature range between liquidus and
solidus temperatures in which molten and solid
constituents coexist.
GD&T
Geometric Dimensioning and Tolerancing
Fluidity
Having fluidlike properties. In die casting: the
distance the molten metal will travel through a
channel before it freezes, at a given temperature.
Gage
A fixture or apparatus that checks the dimensional accuracy of a produced part such as a die
casting. A gage performs no work on the part.
10
10-19
Glossary
Gaging
Gate, center
The process of using a gage to determine if a

part is dimensionally usable.
Galling
Tearing out of particles from a metal surface
by sliding friction.
Galvanic corrosion
Corrosion associated with the current of a
galvanic cell consisting of two dissimilar
conductors in an electrolyte or two similar
conductors in dissimilar electrolytes.
Gas, trapped
A defect in a die casting where gases (such
as air, steam, hydrogen and gases from the
decomposition of the parting material) have
become entrapped within the casting and have
formed one or more voids.
A gating arrangement in a die casting die that

causes the injected metal to enter the cavity
from the center of the part instead of along an
outer edge. The casting must be open in the
center, like a wheel or bezel, to be center gated.
Gating system
The passages, except the cavity, in a die casting
die through which the injected metal must flow.
The gating system includes the sprue or biscuit,
main runner, branch runners (if any), gate
runners, approach, the gate, overflows and vents.
Geometric characteristics
Geometric characteristics refer to the basic
elements or building blocks which form the
language of geometric dimensioning and
tolerancing. Generally, the term refers to all
the symbols used in form, orientation, profile,
runout and location tolerancing.
Globular microstructure
Gate erosion
Die damage induced by the long term hightemperature and high-velocity metal stream
from the die inlet gate(s).
Gate runner
The runner in a die casting die that is directly
adjacent to the gate. The transition from gate
opening to runner cross-section.
Gate
A microstructure in which the primary phase

is globular, rather than dendritic. This is the
typical microstructure for semi-solid castings
after heating to the semi-solid forming
temperature. See also degenerate dendrites.
Gooseneck
In hot-chamber die casting, a spout connecting a metal pot or chamber with a nozzle or
sprue hole in the die and containing a passage
through which molten metal is forced on its
way to the die.
(1) The passage connecting a runner or

overflow with a die cavity. (2) The entire
ejected content of a die, including the casting
or castings and the gates, runners, sprue (or
biscuit) and flash.
10-20
Glossary
Grain
Hard chromium
A region within a solidified metal where the

crystalline structure of the atoms is relatively
perfect. The entire structure of the metal is
made up of such grains. During cooling the
grains are formed by growing larger from
chance joining of atom pairs or from an
impurity. As the grains grow they meet each
other and the crystalline structure ends at
these boundaries.
Grain refinement
The manipulation of the solidification process
to cause more (and therefore smaller) grains
to be formed and/or to cause the grains to
form in specific shapes. The term refinement
is usually used to mean a chemical addition
to the metal, but can refer to control of the
cooling rate.
Grain structure
The size and shape of the grains in a metal.
Grit blasting
Abrasive blasting with small irregular pieces of
ferrous or ceramic material.
Growth
(1) Volumetric increase of a casting as a result
of aging, intergranular corrosion or both. (2)
Growth is the opposite of shrinkage.
Hard anodizing
A variation of the sulfuric acid anodizing process
using lower temperatures and higher voltages.
Hard buffing
Procedure for cutting down rough surfaces
using buffs made with a high thread count and
an aggressive compound.
Chromium that is plated for engineering

rather than decorative applications, and is not
necessarily harder. It provides a wear-resistant
surface and can be used to salvage worn or
undersized parts.
Hard spots
Dense inclusions in a casting that are harder
than the surrounding metal.
Hardware finish
An especially smooth, as-cast surface requiring no polishing and little buffing in preparation for plating.
Heat checking
See Fatigue, thermal.
Heat sink
(1) Feature of a die casting die designed to
remove heat from the die or from a specific
region within the die. Water channels are the
most common type of heat sink. However,
high thermal conductivity materials are also
used. (2) A die casting designed to function as
a heat sink in an assembly.
Heat transfer coefficient

The rate a material will transfer heat energy
per unit time through a distance due to a
temperature difference. The heat transfer
coefficients for different materials are given
in Btu/hr-ft-F and W/m-C. Also called the
Coefficient of Thermal Conductivity.
Hiding power
The ability of a paint to hide or obscure a surface to which it has been uniformly applied.
10
10-21
Glossary
Hole, cored
In a die casting, any hole that is formed by
a core in the die casting die. A cored hole is
distinguished from a hole that is added after
the casting has been made (as by drilling).
Hot-chamber machine
A die casting machine designed with the metal
chamber and plunger, or metal pump, continually immersed in molten metal, to achieve
higher cycling rates.
Hot cracking
A rupture occurring in a casting at or just
below the solidifying temperature by a pulling
apart of the soft metal, caused by internal
thermal contraction stress.
Impact strength
Ability to absorb shock/energy, as measured by
a suitable testing machine.
Impression
(1) A cavity in a die. (2) The mark or recess left
by the ball or penetrator of a hardness tester.
Inclusions
Particles of foreign material in a metallic
matrix. The particles are usually compounds
(such as oxides, sulfides or silicates), but may
be of any substance that is foreign to (and
essentially insoluble in) the matrix.
Ingate
The passage or aperture connecting a runner
with a die cavity.
Hot short
Brittle or lacking strength at elevated
temperatures.
Hot shortness
A tendency for some alloys to separate along
grain boundaries when stressed or deformed
at temperatures near the melting point. Hot
shortness is caused by a low melting constituent, often present only in minute amounts,
that is segregated at grain boundaries.
Hot tear
A fracture formed in a metal during solidification because of hindered contraction. Compare
with hot crack.
Ingot
A pig or slab of metal or alloy.
Injection
The act or process of forcing molten metal
into a die.
Injection profile
The preprogrammed change in speed with
time of the injection ram. Speed is often
changed during the injection stroke to minimize air entrapment and die filling time.
ISIR
Initial Sample Inspection Report
10-22
Glossary
Insert
Laminated object manufacturing (LOM)
A piece of solid material, usually metal,

that becomes an integral part of the casting.
Inserts are commonly set in the die so that
metal is cast around that portion left exposed
in the die cavity. Alternatively, inserts are
often applied subsequent to casting. (Note:
inserts become a part of the casting, whereas
die inserts are a part of the die.)
Intergranular corrosion
A type of corrosion that preferentially attacks
the grain boundaries of a metal or alloy, resulting in deep penetration.
Izod
Name of an impact test and testing machine in
which the specimen is clamped at one end only
and acts as a cantilever beam when struck by
the hammer.
Jewelry finish
The highest-quality, defect-free, electroplated
decorative finish for a die cast part.
A method of rapid prototyping for producing a

prototype part which uses CAD data to position a laser beam over a sheet of heat-activated,
adhesive-coated paper, bonding each layer on
top of the last.
Leveling electroplate
An electroplate that produces a surface
smoother than the substrate.
Logo (logotype)
A symbol used to identify a company, often
cast into a die cast part.
Lot size
The number of pieces made with one die and
machine setup.
Metal distribution ratio

The ratio of the thickness of metal upon two
specified areas of a cathode.
Knock-Out; loose piece

A core positioned by, but not fastened to,
a die and so arranged as to be ejected with
the casting. The knock-out is subsequently
removed and used repeatedly.
Lacquer
A coating composition which is based on
synthetic thermoplastic film-forming material
dissolved in organic solvent and which dries
primarily by solvent evaporation.
Metal extension (flash)

The thin web or fin of metal on a casting
occurring at die partings, air vents and
around movable cores. The excess metal is
due to the working pressure and operating
clearances in the die.
Metal saver
A core used primarily to reduce the amount of
metal in the casting and to avoid sections with
excessive thickness.
10
10-23
Glossary
Metal, hot delivery of
The practice of transferring molten metal from
the smelting plant to the die casting plant.
Hot-metal delivery results in considerable
energy and dross savings since the metal does
not have to be remelted at the die casting
plant. Metal may be transported in the molten
state for several hundred miles.
MHD Casting
Magneto-Hydro Dynamic casting is a casting
process in which the metal is vigorously stirred
by a magnetic field during solidification.
Microthrowing power
The ability of a plating solution or specified
set of plating conditions to deposit metal in
fissures, pores or scratches.
Moving core mechanism

The parts of a die casting die that hold and
move a moving core. These may include gibs,
locking wedge, angled pins, dogleg cams,
racks, pinions and/or hydraulic cylinders.
NADCA
North American Die Casting Association, consolidation of the Society of Die Casting Engineers
and the American Die Casting Institute.
NADCA Product Standards

Die casting product standards originally
published by the American Die Casting
Institute, which this publication supersedes.
ADCI and SDCE (the Society of Die Casting
Engineers) merged to become NADCA, the
North American Die Casting Association.
Nickel plate
A coating of nickel, deposited by electrolytic
or electroless plating methods, for decorative
purposes and corrosion resistance. It is usually
coated with a chromium flash plate for greater
resistance to tarnish and wear.
Nitric acid pickle

A pre-pickle for the ferric nitrate treatment of
magnesium.
Nitriding
A heat treating process for increasing the
surface hardness of tool steels by diffusing
nitrogen into the surface.
Nozzle
The outlet end of a gooseneck or the tubular
fitting that joins the gooseneck to the sprue hole.
Operation, secondary
A manufacturing operation, or step, that
is performed on, or to, a die casting after
the casting is produced but before it is
shipped to the customer or assembled
into the finished product.
Overflow
A recess in a die, connected to a die cavity by a
gate, remote from the entrance gate (ingate).
Overflow gate
A passage or aperture connecting a die cavity
to an overflow.
Net casting yield

See Casting yield.
10-24
Glossary
Oxidation
Parting line, stepped
A reaction in which electrons are removed from a

reactant, as in the formation of ions at the anode
surface in electrolysis. The combination of a
reactant with oxygen or an oxidizing agent.
Oxide coating
A coating produced on a metal by chemical or
electrochemical oxidation for the purpose of
coloring or providing corrosion and
wear resistance.
PPAP
Pre-Production Approval Process
PPM, Parts per Million

The acceptance level for the fulfillment of a
production order based on the number of defective parts permissible per million parts shipped.
A condition on a die casting where the parting

line changes abruptly from one level to another.
Passive stirring
Another process for producing the feed material for semi-solid casting. The liquid metal is
forced through restrictive channels as it cools,
breaking up the dendrites.
Phosphate coating
A conversion coating applied to metal surfaces
for the purpose of improving paint adhesion
and corrosion protection.
Phosphoric acid pickle

A treatment to remove surface segregation
from magnesium die castings and improve
corrosion resistance.
Pickling
Part print
An engineering drawing (sometimes a reproduction of the engineering drawing) showing
the part design. Usually part print refers to
the drawing of a die casting rather than a die,
tool or machine.
Parting face
The surface of a die casting die half that closes
against a mating surface on the opposite die
half. See Surface, parting.
Parting line
The junction between the cover and ejector
portions of the die or mold. Also, the mark left
on the casting at this die joint.
Removing surface oxides by chemical or

electrochemical reaction.
Pin
A core, usually of circular section, normally
having some taper (draft). Also, a dowel (or guide
pin) to ensure registry between two die sections.
Pitting
The appearance of small depressions or cavities
produced during solidification or as a result of
corrosion and cavitation.
Platen
Portion of a casting machine against which die
sections are fastened, or of trim presses against
which trim dies are fastened.
10
10-25
Glossary
Plating rack
A frame for suspending parts and carrying
current to articles during plating operations.
Plunger
Port through which molten metal is ladled into

the cold-chamber of a die casting machine.
Powder coating
Combination of tip and rod that forces metal

into the die.
Polishing
The smoothing of a metal surface by means
of the action of abrasive particles attached by
adhesive to the surface of wheels or endless
belts usually driven at a high speed.
Porosity
Voids or pores, commonly resulting from
solidification shrinkage; air (primarily the
nitrogen component of air) trapped in a casting
or hydrogen exuded during electroplating.
Porosity dispersion
The degree to which the porosity is spread
throughout the casting, as opposed to being all
in one place.
Porosity, internal
Porosity that is completely encased within the
die casting.
Porosity, surface
Porosity in a die casting that is open to the
surface of the casting.
Port
Opening through which molten metal enters
the injection cylinder of a hot-chamber
machine or is ladled into the injection cylinder
of a cold-chamber machine.
10-26
Pouring hole/slot
This method involves electrostatically spraying

a premixed granulated powder onto a workpiece
and then curing at an elevated temperature to
obtain final coating properties. Powder coating
has many advantages, including the absence
of organic solvents, a wide choice of coating
materials for many service conditions, minimal
material waste, and easy handling.
Preheating
The process of heating a die casting die prior
to making castings to minimize the thermal
shock from the first few castings. Also applies
to die heating prior to die placement in the
machine, for more rapid die changing and
onset of production.
Press, trimming
A power press (either mechanical or hydraulic)
used to trim the flash, runners and overflows
from die cast parts after casting.
Pressure tightness
A measure of the integrity of a die casting
in which a fluid under pressure will not pass
through the casting. The method of testing
and the pressure used must be specified.
Process capabilities
The range, or variation, of critical casting
quality parameters (such as dimensional
tolerances) within which a particular die and
machine combination will operate.
Glossary
Quench
Rapid prototyping
The cooling of a die casting from its ejection

temperature to room temperature.
Quench, water
The cooling of a die casting from its ejection
temperature to room temperature (or to nearly
room temperature) by placing it in water.
Quick-Change
(1) Any construction for a tooling component
that allows the component to be replaced
without removing the tool or die from the
machine in which it is operated. (2) Die
casting die features and procedures, such as
preheating, which enable dies to be changed
on die casting machines with a minimum of
interrupted production. Such features usually
add cost to the original construction of the
tool or die, but can save considerable machine
downtime costs.
R&R
Repeatability and Reproducibility.
Radiograph
A picture produced on a sensitive surface, as a
photographic plate, by electromagnetic radiation of wavelength less than 500 angstrom
units. The most common is the X-ray. X-ray
pictures of die castings can often reveal flaws
inside the castings.
Radius
A convex arc blending two surfaces on a die
casting or on the model from which a die
casting is to be made. See Fillet.
Production of a full-scale model of a proposed

design more quickly and inexpensively than by
traditional methods like single-cavity prototype die casting, gravity casting or machining.
See also: Stereolithography, Selective laser
sintering, Laminated object manufacturing.
Reclaim
The process of smelting trimmings, scrapped
parts, dross and machine turnings back to
original alloy specifications.
Refine
In magnesium melting practice, the removal
of magnesium oxide and other suspended
non-metallic matter by use of flux that preferentially wets the impurities and carries them
to the bottom of the pot as sludge.
Reflective defect
A casting surface defect that reflects an
undesirable surface condition of the die cavity
steel. For example, fatigue or heating checking
of the die steel may manifest itself as cracks
and craters in the steel. This will leave raised
features on the casting that reflect the die
surface condition.
Release agent
A material that is applied to the surface of the
die cavity to keep the casting from sticking to the
die. Such materials are usually applied frequently,
sometimes every cycle, and are usually applied by
spraying. To facilitate the spraying, the material
is mixed with water or a mineral solvent which
evaporates from the cavity surface.
Remelt
Sprues, gates, runners and as-cast defective
castings returned directly to the melting pot.
10
10-27
Glossary
Rheocasting
Another term for semi-solid metal casting.
Rib
A wall normal to a second wall or surface to
strengthen or brace the second wall or surface.
Robber
See Cathode robber.
SDCE
Society of Die Casting Engineers, which
merged with the American Die Casting
Institute to become the North American Die
Casting Association (NADCA).
Sealed chrome pickle

A treatment for magnesium consisting of
a chrome pickle, followed by sealing in a
dichromate solution.
Sealing of anodic coating

Runaround scrap
See Remelt.
Runner
A die passage connecting the sprue hole or
plunger hole of a die to the gate or gates where
molten metal enters the cavity or cavities.
Salt fog test

An accelerated corrosion test in which specimens are exposed to a fine mist of a solution
usually containing sodium chloride.
Satin finish
A surface finish that behaves as a diffuse
reflector, which is lustrous but not mirror-like.
Scale
A build-up of material that forms on the die
cavity surface during the operation of the die
casting die. The build-up material is usually a
combination of the oxide of the metal being cast
and the parting material. The scale leaves an
imprint on the casting and in extreme instances
can even change dimensions on the casting.
10-28
A process which, by absorption, chemical reaction or other mechanism, increases the resistance
of an anodic coating to staining and corrosion,
improves the durability of colors produced in the
coating or imparts other desirable properties.
Section, heavy
Any place in a die casting where the thickness
is significantly greater than (at least double)
that of the majority of the casting.
Segregation
Non-uniform distribution of alloying elements, impurities, or microstructures.
Selective laser sintering (SLS)

A method of rapid prototyping which uses a
modulated laser beam on specialized powders to
transform CAD data into full size prototypes in
polycarbonate, nylon, or investment wax.
Semi-bright nickel
Nickel plate, containing less than 0.005%
sulfur, that requires polishing to give full
brightness or is used as-plated for the bottom
layer in a double-layer nickel plate.
Glossary
Shield
Shrinkage, internal
A nonconducting medium for altering current

distribution on an anode or cathode.
Shot
Die filling or part of the casting cycle in which
molten metal is forced into the die.
Shot peening
The procedure of impacting a metal surface
with a high-velocity stream of metal shot or
glass beads for the purpose of (1) cleaning or
(2) improving resistance to stress corrosion by
producing a compressive stress.
Shot size
The cubic volume of a die cast shot or the
cubic volume of die casting alloy that a die
casting machine is capable of injecting into
a die. Shot sizes are sometimes expressed in
weight or mass units.
Shrink mark
A surface depression, often called a shadow
mark, that sometimes occurs at a thick section
that cools more slowly than adjacent sections.
Also known as a sink.
Shrinkage factor
See Contraction factor.
Shrinkage pits
A condition on a die casting where the
solidification shrinkage has resulted in small
holes on the surface of the casting. These
holes are sometimes called heat holes.
When they form along the gate, they are
called gate holes.
Condition during the solidification of a casting

where volumetric shrinkage results in the
formation of a void inside the casting.
Shrinkage, solidification
Volume reduction that accompanies the freezing (solidification) of metal in passing from the
molten to the solid state.
SIMA
(Strain Induced, Melt Activated) A wrought
process for producing feed material for semisolid metal casting. The metal is generally hot
extruded and cold drawn.
Skin
See Die cast skin.
Sleeve, shot
The molten metal chamber of a coldchamber die casting machine. This is a
hardened steel tube through which the shot
plunger moves to inject the molten metal
into the die. See Cold chamber.
Slide
Portion of a die generally arranged to move
parallel to the parting line. The inner end
forms a part of the die cavity wall and sometimes includes a core or cores.
Slug
See Biscuit.
SMED
10
Single minute exchange of dies, a technique

from Lean Manufacturing disciplines to
reduce die set up times.
10-29
Glossary
Soldering
Staking
The sticking or adhering of molten metal to

portions of the die following casting.
Solidification shrinkage
See Shrinkage, solidification.
Solution heat treatment

Heating an alloy to a suitable temperature,
holding at that temperature long enough to
allow one or more constituents to enter into
solid solution and then cooling rapidly enough
to hold the constituents in solution.
SPC, statistical process control

Statistical techniques to measure and analyze the
extent a process deviates from a set standard.
Sprue
Metal that fills the conical passage (sprue hole)
that connects the nozzle or hot chamber to
the runners of a hot-chamber machine. (Most
cold-chamber machines form a biscuit and
have no sprue.)
Sprue pin
A tapered pin with rounded end projecting
into a sprue hole and acting as a core to keep
the casting in the ejector portion of the die.
Sputter coating
The formation of a deposit by the condensation of atoms or particles formed by ejection
from a surface subjected to high-energy ion
bombardment.
A cold forming operation to a die casting.

Staking is usually performed in a power press
to bend tabs or swage heads onto studs.
Stereolithography
A method of rapid prototyping which converts
3-D CAD data into a series of very thin slices
and uses a laser-generated ultravioliet light
beam to trace each layer onto the surface of a
vat of liquid poly-mer, forming and hardening each layer until the complete, full-size
prototype is formed.
Strength, ultimate tensile

The maximum tensile (pulling) stress a metal
can stand before rupturing.
Strength, yield
The stress at which a material exhibits a specified limiting permanent strain or permanent
deformation.
Stress corrosion cracking

Cracking due to the combined effects of stress
and corrosion. Usually this type of failure
occurs as a fine hairline crack that propagates
across the section without any exterior sign of
corrosion.
Stress
Force per unit area. When a stress is applied to
a body (within its elastic limit) a corresponding
strain (i.e., change in shape) is produced, and
the ratio of strain to stress is a characteristic
constant of the body.
SQC, statistical quality control

Statistical techniques to measure and improve
the quality of a given process.
10-30
Glossary
Stress, thermal
Stress induced into a material when a
temperature change causes a force trying to
change the size or shape of the part, but the
part is restrained and cannot re-spond to the
thermally induced force.
T&T
Void
A large pore or hole within the wall of a casting
usually caused by solidification shrinkage or gas
trapped in the casting. Also, a blow hole.
Water line
See Cooling Channel.
Taper and Tolerance.
TQM
Total Quality Management.
Unit system
Wet blasting
A process for cleaning or finishing by means of
a slurry of abrasive in water, directed at high
velocity against the parts being processed.
Wire brushing
A die casting die built to a standardized

design and dimensions. Also, a series of units,
for a variety of castings, that are installed and
run in the die holder as the need for various
castings dictates.
The method of burr removal, edge blending

and surface finishing by contacting the work
surface with a variety of rotating wire brushes.
Yield
Vacuum
See Casting yield.
A space completely devoid of matter, even

gases. Shrinkage voids in a die casting can
be a vacuum. It is not necessary for a void to
include entrapped air.
Vacuum assist
The action of voiding the die casting die of
gasses during or prior to the flow of molten
metal to form the casting.
ZA
A designation followed by a number, which
is used to designate a group of three zinc
based casting alloys. The number indicates the
approximate nominal aluminum content.
Zamak
An acronym for zinc, aluminum, magnesium
and copper, used to designate the zinc alloys
2, 3, 5 and 7.
Vent
A thin narrow passage that permits air to escape
from the die cavity as it is filled with metal.
Vibratory finishing
10
A process for deburring and finishing

mechanically by means of abrasive media in a
container subjected to high-rate oscillations.
10-31
Glossary
10-32

NADCA Product Specification Standards For Die Casting

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NADCA Product Specification

Standards for Die Casting

Arlington Heights, Illinois

Revised for 2015

NADCA Product Specification

The North American Die Casting Associations mission is

Product Standards Disclaimer

Revisions and Additions Schedule

NADCA Product Specification Standards for Die Castings / 2015

Cross Reference to NADCA Standards,

List of NADCA Standards, Guidelines and Checklists

Current Revisions and Additions

Process and Material Selection for Product Recyclability

Tooling for Die Casting

Engineering & Design: Coordinate Dimensioning

Engineering & Design: Miniature Die Casting

Engineering & Design: Geometric Dimensioning

Engineering & Design: Additional Specification Guidelines

Index/ Glossary of Die Casting Terms

NADCA Product Specification Standards for Die Castings / 2015

Introduction to this Manual

Composition & Properties of

Composition & Properties of

Composition & Properties of

Composition & Properties of

Composition & Properties of

Production Part Orders

Die Casting Dies & Production Tooling

Checklist for Die Casting

Checklist for Finished Die Cast

Drawing & Specifications

Gage, Measurements & Test Equipment

Statistical Quality Control

Certified Zinc Alloy Plan for Die Casting

NADCA Product Specification Standards for Die Castings / 2015

Pressure Tight Castings

Linear Dimension Tolerances

Parting Line Tolerances

Moving Die Component Tolerances

(1) (See below)

Depth of Cored Holes

(1) (See below)

Draft Requirements in Cored Holes

Cored Holes for Threads

Ejector Pin Marks

Engrg. & Design

Engrg. & Design

Machining Stock Allowance

Die Cast Threads

Fillets, Ribs & Corners

Lettering & Ornamentation

Surface Finish, As-Cast

Alloy Data Tables

Alloy Cross Reference Designations

NADCA Product Specification Standards for Die Castings / 2015

Aluminum Matrix Composites

Zinc and ZA Alloys

Cored Holes for Cut Threads Tolerances

Engineering & Design: Miniature Die Castings

2) I s there some comparison between recycled aluminum and virgin aluminum?