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Magnesium
Injection
Molding
DESIGN GUIDE
PHILLIPS PLASTICS CORPORATION
What is Magnesium
Injection Molding?
Magnesium injection molding (MAG) produces
components with attributes that include superb
quality, high repeatability, dimensional precision,
and design flexibility. The magnesium injection
molding process is similar to plastic injection
molding, with mechanical properties equivalent
to or better than die-cast components. Phillips
The Magnesium
Molding Process
Magnesium injection molding is a single step,
semi-solid molding process that combines the
best of plastic injection molding and die-casting.
Chips of magnesium alloy are fed into a heated screw and barrel where the alloy is thermally and
mechanically processed into a semi-fluid state and is injected directly into the tool cavity. In contrast
to the higher temperatures necessary for die-casting, magnesium injection molded components are
processed at temperatures more than 100 degrees Fahrenheit cooler. The resulting semi-solid properties
allow the metal alloys to flow like a thermoplastic with a more controlled, laminar flow. The magnesium injection molding process delivers net shaped components with many inherent benefits which
include: superior strength to weight ratios, EMI/RFI shielding, better straightness and flatness, heat
dissipation, low porosity, and tighter tolerances, which may reduce or eliminate some secondary
machining operations.
Thixotropic Structure
Conventional dendrite
formation in semi-solid alloy
Thixotropic structure
of semi-solid alloy
resulting from stirring
Conventional Die-Casting
Cold Chamber
Hot Chamber
Prototype Capabilities
EMI/RFI
Secondary Operations
Machining
Capability Options
Environmental Considerations
Magnesium injection molding is an environmentally friendly, 100% recyclable process
that uses no ozone layer depleting gases.
A closed operating system, running at lower
than melting temperatures, eliminates molten
metal hazards and prevents the generation
of oxides. Magnesium, weighing 1/4 the
weight of steel and 1/3 lighter than aluminum,
is the eighth most abundant element in the
earths surface and can be safely manufactured in a low hazard environment.
Assembly Considerations
Metallurgical Lab
Design Considerations
Walls and Wall Thickness
The walls should be kept as uniform in thickness as possible. Thick sections will be more likely to have
porous centers than thin ones. The magnesium injection molding process has the ability to produce
a higher percent of solids than conventional die-casting thus reducing porosity issues. Magnesium
injection molding can produce walls as thin as 0.015 inch. A general rule is that the flow distance of
the metal will be 100 times the thickness of the wall. However, Phillips has experience with walls as
thin as 0.050 inches with flow distances as much as 6 inches (120 times the thickness). The ability to
place a gate close to the thin sections to be filled, greatly enhances successful filling of thin walls.
Wall thickness should be as uniform as possible to avoid local hot spots during solidification.
Draft
Inserts
Undercuts
Hinges
Creep
Snap Fits
Flammability
Dimensional
Considerations
Dimensional Considerations
Magnesium injection molded components may be designed to a tighter tolerance than conventional
die-castings. Phillips has found that magnesium injection molded components can be designed using
North American Die Cast Association (NADCA) Precision Standards. The superior dimensional
stability of the magnesium injection molding process allows the designer greater flexibility in
design, while holding tighter tolerances.
Moving Die
Precision Tolerance
Added to Linear Dimension (Projected Area)
Up to 21 to 50 inches2
+ 0.004
51 to 100 inches2
+ 0.006
+ 0.008
+ 0.011
Linear Dimension
Precision Tolerance
Basic Tolerance
Up to 1 inch (25.4 mm)
0.002
( 0.05 mm)
Additional Tolerance
For each additional inch
0.001
( 0.025 mm)
Linear Tolerances
0.05
0.045
Tolerance in Inches
0.04
0.035
0.03
0.025
0.02
0.015
0.01
0.005
0
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)
Cu Standard Tolerance
Cu Precision Tolerance
Flatness
Precision Tolerance
Maximum Dimension of Die-Cast Surface
Up to 3.00 inches
0.005
(76.20 mm)
(0.13 mm)
Additional Tolerance
For each additional inch
0.002
(25.4 mm)
(0.05 mm)
Flatness Tolerance
0.05
0.045
Tolerance in Inches
0.04
0.035
0.03
0.025
0.02
0.015
0.01
0.005
0
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)
Parting Line
Precision Tolerance
Added Linear Tolerance (Projected Area)
Up to 10 inches2
+ 0.0035
11 to 20 inches2
+ 0.004
+ 0.005
21 to 50 inches2
51 to 100 inches
+ 0.008
2
2
+ 0.012
+ 0.016
Tolerance in Inches
0.025
0.02
0.015
0.01
0.005
10
20
50
100
200
300
(64.50)
(129.0)
(322.6)
(645.2)
(1290)
(1935)
Cu Standard Tolerance
Zn Standard Tolerance
Cu Precision Tolerance
Zn Precision Tolerance
Draft
Precision Tolerance
Minimum precision draft for inside walls is
generally recommended at 0.75 degrees
per side, with outside walls requiring half
as much draft.
Draft should be calculated based on the
formula shown in the Draft Requirements
Section of the NADCA standard.
Source: NADCA Product Specification
Standards for Die Casting/Sec. 4A/2000
Equipment List
Molding Equipment
2 220 metric ton or 245 U.S. ton Thixomolder
2 500 metric ton or 550 U.S. ton Thixomolder
2 650 metric ton or 715 U.S. ton Thixomolder
1 850 metric ton or 935 U.S. ton Thixomolder
Deburring Equipment
4 cu. ft. to 18 cu. ft. vibratory deburring machines
1 tumble/blast deburring machine
Tooling
Machining Equipment
Assortment of CNC and special purpose
machining equipment
Tool Construction
Lab
Metallographical sample preparation equipment
Olympus 1x70 metallurgical microscope
Archimedes density measurement device
Machine Specifications
Locking Tonnage
Tool Life
500,000 shots
150,000 shots
LxWxT
Injection Volumes
0.1 lb to 12 lb
(45 grams to 5445 grams)
Projected Area
Coatings
Electrodeposition (e-coat) Process
The e-coat process applies paint to the part in a tank of water-based solution.
The paint is grown on the surface using electricity and covers the entire part
with a uniform coating. These paint tanks are dedicated to one paint only and are
not changed. Various colors or gloss levels of paint are available, but only one is
dedicated to the tank due to the high cost of change-over. For full coverage of
paint on the part, this efficient system could be the least expensive coating process.
Chromate
Non-Chromate
Iron Phosphates
Alodine
Anodizing
Tagnite
Keronite
Anomag
Powder Coating
Types of Plating
Electroless plating a chemical process
used to deposit layers of copper and nickel
Liquid Paints
Hydrographics
A process used to apply a pattern finish to threedimensional parts, adding cosmetic appeal and
surface protection to the product.
Corrosion
As with many active metals, corrosion is an issue
that should be addressed early in the design of the
component. Todays high purity magnesium alloys
exhibit excellent corrosion resistance and can be used
with confidence in many applications. The two types
of corrosions that are addressed are atmospheric
and galvanic.
Atmospheric Corrosion
Unprotected magnesium alloys exposed to atmospheres that do not contain salt spray will develop
a gray film. This film will provide some corrosion
protection; however, if the surface comes in contact
with materials that hold moisture or chlorides and
sulfates, the unprotected surface will corrode. This
type of corrosion is easily overcome by the proper
application of a suitable surface coating.
The following table depicts magnesium alloy corrosion rates (using a standard ASTM test) compared to
aluminum and steel. The most popular magnesium
alloy, AZ-91-D, corrodes significantly less than either
carbon steel or 380 aluminum.
Carbon Steel
30
13
13
13
Galvanic Corrosion
Group #2
Group #3
Group #4
(Least effect)
Group #5
(Greatest effect)
Aluminum Alloys
Aluminum Alloys
Alclad 2024
Zinc-plated Steel
Low-carbon Steel
5052
6063
Aluminum Alloys
Cadmium-plated Steel
Stainless Steel
5056
7075
2017
Monel
6061
3003
2024
Titanium
Alclad 7075
Zinc
Lead
Copper
Brass