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Magnesium Die Casting of Engine Parts
Magnesium Die Casting Engine Parts are near-net-shape precision metal components manufactured by injecting molten magnesium alloy into hardened steel molds under high pressure and rapid solidification.
Description
Product Overview
Magnesium Die Casting Engine Parts are near-net-shape precision metal components manufactured by injecting molten magnesium alloy into hardened steel molds under high pressure and rapid solidification.
Technical Data
| Item | Capability |
| Process | High Pressure Die Casting (HPDC) |
| Casting Material | AZ91D / AM60 / AM50 / AZ31 Magnesium Alloys |
| Die Casting Machine Range | 280T – 2500T High Pressure Die Casting Machines (for magnesium die casting engine parts production) |
| Part Weight Range | 0.05 – 10 kg |
| Maximum Part Size | Up to 800 mm (geometry dependent) |
| Dimensional Tolerance | ±0.02 mm (precision features), general ±0.05 mm |
| Surface Roughness (As-cast) | Ra 1.6 – 3.2 μm |
| Wall Thickness Range | 1.5 – 5.0 mm (optimized 2.0 – 4.0 mm) |
| Minimum Wall Thickness | ~1.0 mm (design dependent) |
| Draft Angle | 0.5° – 2° |
| Production Volume | Prototype / Low volume / Mass production up to 500,000+ pcs/year |
| Mold Type | H13 / SKD61 equivalent steel dies |
| Mold Life Expectancy | 50,000 – 200,000 cycles |
| Injection Pressure | 30 – 70 MPa |
| Filling Speed | 0.5 – 50 m/s |
| Solidification Time | 0.01 – 0.2 s |
| Porosity Control | Vacuum-assisted HPDC + process-controlled solidification |
| Casting Density Control | High-integrity pressure solidification |
| Secondary CNC Machining | CNC milling / turning / drilling / tapping / reaming |
| Machining Tolerance | Up to ±0.01 mm |
| Thread Capability | Metric / UNC / custom threads |
| Hole Diameter Capability | ≥ 0.8 mm |
| Leak Testing | Air / helium leak testing available |
| Pressure Testing | Structural validation available (application dependent) |
| Heat Treatment | T5 / T6 (material dependent) |
| Surface Treatment | Powder coating / painting / conversion coating / blasting / polishing |
| Corrosion Protection | Conversion coating + coating systems (up to 240h+ salt spray depending on spec) |
| Inspection Equipment | CMM / projector / height gauge / hardness tester / leak tester |
| Inspection Standard | ISO-based QC system with IATF 16949-compliant process control for magnesium die casting engine parts manufacturing |
| Design Support | Advanced DFM & Mold Flow Simulation (Porosity, Shrinkage & Air Entrapment Prediction for magnesium die casting engine parts before tooling release) |
| File Formats Supported | STEP / STP / IGES / DWG / DXF / PDF |
| Packaging | Export-grade protective packaging (foam / carton / wooden crate / pallet) |
| Shipping Options | Sea / Air / Express logistics |
Manufacturing Process
Drawing Review
↓
DFM Analysis (including manufacturability, cost optimization, and lightweight design validation)
↓
Tooling Design
↓
Mold Manufacturing
↓
Magnesium Alloy Melting
↓
High Pressure Die Casting
↓
Trimming & Deburring
↓
CNC Machining (if required)
↓
Surface Treatment
↓
Inspection (including dimensional + functional + leak testing where applicable)
↓
Packaging & Shipment
Applications
Engine housings
• Covers
• Gearbox housings
• Transmission cases
Electric Vehicles (EV / HEV)
• Battery housings
• Motor controller housings
• Electric drive structural parts (lightweight integration for extended EV range and improved thermal performance)
Motorcycle Industry
• Engine covers
• Structural engine components
Industrial Equipment
• Lightweight housings
• Mechanical enclosures
Custom Manufacturing
Capabilities
• OEM / ODM production
• Tooling development
• Prototype manufacturing
• Small batch production
• Mass production
• DFM engineering optimization
• Full machining integration
• Automotive-grade production support (process control, traceability, and quality documentation available)
Supported Files
STEP / STP / IGES / DWG / DXF / PDF / SLDPRT
Quality Control & Inspection
Incoming Material Inspection: Chemical composition verification, batch traceability control
First Article Inspection (FAI): Full dimensional verification before mass production release
In-Process Inspection: Key dimension monitoring during production runs
Dimensional Inspection: CMM-based geometric and tolerance verification
Functional Inspection: Assembly fit and critical interface checking
Leak Testing: Air / helium leak testing available for sealed components
Pressure Testing: Structural integrity verification for pressure-bearing parts
Final Inspection: 100% visual and dimensional check before shipment
Packaging Inspection: Final verification of protective packaging and labeling compliance
Quality System Certification: IATF 16949:2016 Certified (for automotive-grade manufacturing system control and process traceability)
Process Control System: SPC (Statistical Process Control) applied for high-volume production stability, defect prevention, and continuous quality improvement
Packaging & Logistics
Protective wrapping
• Foam protection
• Bubble packaging
• PE bags
• Cartons
• Wooden crates
• Pallet shipment
Shipping methods
• Sea freight
• Air freight
• Express delivery
FAQ
Q: Why choose magnesium die casting engine parts instead of aluminum?
A: Magnesium offers 35% weight reduction, improving fuel efficiency and EV range, while providing significantly higher vibration damping for engine and powertrain systems.
Q: How do you control porosity in magnesium die cast engine housings?
A: We use vacuum-assisted HPDC + X-ray NDT inspection + 100% leak testing, ensuring internal structural integrity for pressure-critical components.
Q: What is your lead time for tooling and prototype samples?
A: Typical tooling lead time is 30–45 days, with FAI sample delivery after DFM approval depending on part complexity.
Q: Can you manufacture based on customer CAD drawings?
A: Yes, we support STEP / IGES / DWG / SLDPRT files with full DFM engineering review before tooling.
Q: How do you ensure corrosion resistance of magnesium components?
A: We apply conversion coating + powder coating / e-coating systems, validated through salt spray testing up to 240+ hours depending on specification.
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