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Magnesium Die Casting

Thinwall magnesium die casting w/ built-in EMI/RFI shielding

Thinwall, hot-chamber magnesium die casting was used for this Kodak camera housing. It provided exceptional built-in EMI/RFI shielding needed for the design.  Magnesium makes it possible to create a thinner profile with the equivalent strength of heavier metals.  


Magnesium Die Casting Team Leader Casey W works with magnesium parts

Casimir (Casey) Wisniowicz
Magnesium Die Casting Team Leader
Employed since 1984

Magnesium is the light-weight champion of all die casting metals.

If your project requires a lightweight die casting component with an excellent strength-to-weight ratio, magnesium die casting is the logical option. CWM die casts magnesium alloy AZ91D, a high-purity alloy which offers good corrosion resistance for your magnesium parts, as well as the following benefits:

  • Longer tool life
  • Easiest alloy to machine
  • Good thermal and electrical conductivity
  • Excellent for thin-wall, complex parts
  • Excellent noise and vibration dampening properties
  • Provides excellent EMI & RFI shielding
  • Good finishing characteristics
  • Light weight (75% lighter than steel, 33% lighter than aluminum) with high strength
  • Magnesium parts scrap material is 100% recyclable

What is Magnesium?

Magnesium Die Casting Ingots for magnesium parts in various industries

Magnesium is a base material for numerous alloys. AZ91D is the most common magnesium alloy for die casting. It offers very good castability and toughness, and is an ideal material for light weight, highly durable parts.

Hot-Chamber Die Casting

Chicago White Metal uses hot-chamber die casting to produce die cast magnesium parts. In this process, the metal injection components are submerged in a reservoir of molten magnesium. A hydraulically-powered piston forces the magnesium into the die, taking advantage of magnesium’s excellent flow characteristics to accurately produce complex shapes.

Magneisum Parts - Scope Housing that used CWM's magnesium die casting processes.  Why Choose Magnesium for your Die Casting Project?

Compared to steel, magnesium is 75% lighter with no significant loss of strength. It is a far better material for complex, thin-walled, net shape or near-net shape castings and offers greater dimensional stability. Magnesium castings can meet tight tolerances that would be difficult or impossible to achieve with steel. Tooling costs can be lower for magnesium castings, as multiple parts can be easily consolidated into a single component. This also improves component rigidity and reduces welding and assembly costs.

Compared to aluminum, magnesium is 33% lighter, with similar or improved mechanical properties, and machines easier. Magnesium provides greater corrosion resistance, and is better suited to large, thin-wall, net shape complex parts.

Magnesium Die Casting Primary Benefit of Mg Secondary Benefit of Mg
vs. Steel Weldment 75% Lighter Less Expensive
vs. Aluminium Die Casting 33% Lighter Longer Tool Life
vs. Plastic Molding Stronger, stiffer Environmentally Stable

Magnesium is stronger and stiffer than even the most advanced engineered plastics. It also provides greater wear resistance, higher temperature resistance, and better energy absorption/impact resistance characteristics.

Chicago White Metal was the first hot-chamber magnesium die casting company in North America and operates one of the largest, most advanced facilities for magnesium die casting. With 8 magnesium die casting machines from 200 to 650 tons of locking force, CWM can produce magnesium parts in a range of sizes from 0.75" x 0.75" to 18" x 18".

Request a quote or contact Chicago White Metal to discuss your project.

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