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Cast through the rubber plaster molding process in AZ91D magnesium alloy, this projector frame and interface offered the customer improved durability and rigidity, high heat tolerance and eliminated EMI plating requirements when compared to its previous plastic injection mold design.


This characteristic is important where resistance to deflection is desired in a lightweight component. Improved Die Life—Unlike molten


mechanical properties at higher tempera- ture ranges in service.


Design Considerations When evaluating the various alloys


and processes for a magnesium casting,


the end-use application, post-casting operations and tooling costs should be considered to obtain a quality, low-cost component. Specifi cally, remember the following attributes of magnesium: High Stiffness-to-Weight Ratio—


aluminum, molten magnesium does not react with tool steels, resulting in longer die life and increased produc- tivity. Because of low erosion and heat input, which reduce the propensity for thermal fatigue (heat checking of the die), casting magnesium can achieve three to four times the die life than can be achieved with aluminum. Machining—Magnesium is recog-


nized as the easiest of structural metals to machine and is the standard of the cutting tool industry when comparing machin- ability of metals. The low power require- ments for machining magnesium alloys permit the use of deeper cuts and higher feed rates, thus permitting fast and effi - cient machining when compared to other metals. Magnesium alloys also normally produce well-broken chips, which are easy to handle.


METAL


This article was adapted with permission from materials prepared by the Interna- tional Magnesium Association, McLean, Va., and the North American Die Casting Association, Wheeling, Ill.


The conversion of this military helicopter transmission housing from a fabrication to a magnesium casting allowed for a 30% cost reduction and lowered scrap rates by 40%.


38 METAL CASTING DESIGN & PURCHASING 2011 CASTING SOURCE DIRECTORY


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