ARCHIVES

ISSN (1897-3310)
Volume 9
Issue 2/2009
53-56

Of
FOUNDRY ENGINEERING

12/2

Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences

Microstructure of high-pressure
die-casting AM50 magnesium alloy
K.N. Braszczyska -Malik1a*, R. Dbrowski, J. Braszczyski1b

Czstochowa University of Technology, aInstitute of Materials Engineering, bDivision of Foundry,

Al. Armii Krajowej 19, 42-200 Czstochowa, Poland,
2
FINNVEDEN Metal Structures Sp. z o.o., ul. Wyzwolenia, 43-300 Bielsko-Biala, Poland
*Corresponding address: e-mail: kacha@wip.pcz.pl
Received 26.02.2009; accepted in revised form: 30.03.2009

Abstract
Microstructure analyses of high-pressure die-casting AM50 magnesium alloy are presented. Investigated pressure casting was
produced on a cold chamber die-casting machine with locking force at 1100 tones in FINNVEDEN Metal Structures. Light microscopy
and X-ray phase analysis techniques were used to characterize the obtained material. In microstructure, an D-Mg solid solution, Al12Mg17
and Al8Mn5 intermetallic compounds were observed. Different structural constitutes, which consist impurities, were not disclosed.
Key words: AM50 magnesium alloy, high-pressure die-casting, microstructure

1. Introduction
Magnesium alloys are light metallic structural materials,
which are very attractive in such applications as automobile,
aerospace and electric industries. The high-pressure die-casting
magnesium components are being increasingly used because of
the excellent castability and properties that magnesium offers.
High-pressure die-casting of thin walled components is
particularly suitable due to the exquisite flow characteristics of
molten magnesium alloys [1-6].
The die-casting technology for magnesium and aluminum
alloys is basically similar. However, there are important
differences like handing of the molten alloy. A melting of
magnesium is also different from other metals because it requires
protection against surface oxidation. It should be noted that
magnesium and aluminum die-casting alloys also possess
different chemical and physical properties, which require
modifications in injection parameters and die design. The lower
density of magnesium vs. aluminum signifies that the inertia is

less, and for the same metal pressure a higher flow speed results.
Hence, it will take a shorter time to fill a give die with magnesium
than with aluminum. However, for thin walled products with large
flow distance, the required die filling time will be very short for
magnesium due to the low heat content. Both cold chamber and
hot chamber die-casting machines are used extensively for
magnesium alloys high-pressure die-casting. Static casting
pressures for cold chamber die-casting machines are commonly in
the range 30-70 MPa (4400-10000 psi). In hot chamber process,
static metal pressures are usually less than in cold chamber
machines, typically in the range 20-30 MPa (2900-4400 psi) [611].
Commercial magnesium alloys for die-casting process are
based on Mg-Al system. The most commonly used magnesium
alloys are the AZ91 and AM series [7, 12-14], in which aluminum
constitutes the base alloying elements. Aluminum improves the
mechanical strength, corrosion properties and castability. Because
increasing aluminum content gradually reduced ductility and
fracture toughness, the AM-series alloys (with reduced aluminum
content) are used especially for automotive industry where safety

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considerations are predominant. Manganese is added to control

the iron content in the alloys (improving indirectly corrosion
resistance).
In the present paper, characterization of the microstructure of
AM50 magnesium alloy in high-pressure die-casting condition
was presented.

2. Experimental procedures
Investigated material was obtained at the cold chamber diecasting line in the FINNNVEDEN Metals Structures (BielskoBiaa, Poland). Figure 1 illustrates the scheme of the cold chamber
die-casting line for magnesium alloys. Main elements of a single
casting cell were:
two furnaces,
single-chamber crucibles,
molten metal gas protection system,
metering system consisted of pump and tube transporting
molten metal form the furnace to the casting machine,
temperature control system,
die-casting machine with shot control/monitoring,
die temperature controllers,
die spraying device,

robot for part extraction.

In resented Technology two single-chamber crucible furnaces
were used. One crucible was used for smelting, the other for
maintaining the heat level. The liquid magnesium alloy was
transported without any problems from the smelting furnace to the
holding furnace via a heated U tube. Metering molten metal to
the shot sleeve was realized through the pump. Due to a strong
tendency of molten magnesium to be oxidized, it was prerequisite
to use a protective gas atmosphere over the molten metal in all
casting cycle. A mixture of ca. 1.5% SO2 in dry air was used.
In presented work, a Ital Presse cold chamber die-casting
machines with locking force at 1100 tones was used. The
commercial AM50 magnesium alloy in the form of ingots
produced in China was used. Figure 2 shows the photograph of
the obtained AM50 magnesium alloy pressure casting (centre
stack frame HVAC premium for Volvo V70, XC70, S80 and
Land Rover Freelander 2). The volume of production of this
casting was 173 298 units in 2008 year. For safety reasons ingots
were preheated prior to immersion in the molten metal. Presented
casting was produced at metal temperature of 953 K, speed of
piston rod of 4.5 5.0 m/s, speed at the gates in side mould about
50 m/s, die temperature of c.a. 453 K.

Fig. 1. Scheme of the cold-chamber die-casting line for magnesium alloys

Chemical composition of the obtained AM50 casting were

verified by using a Metal LAB 75/80 optical emission
spectrometer. The specimens for chemical composition analyses
were cut from areas marked as X and Y in Fig. 2. The specimens
for microstructure analyses were cut from parts marked as 1 and 2

54

in Fig. 2. These specimens were prepared by the standard

metallographic technique of grinding and polishing followed by
etching in a solution of 1% nitric acid in ethanol. Microstructural
examination was performed in a light microscope. Phase

A R C H I V E S O F F O U N D R Y E N G I N E E R I N G Vo l u m e 9 , I s s u e 2 / 2 0 0 9 , 5 3 - 5 6

constitutions of alloy were analyzed by X-ray diffraction (XRD).

The Co KD X-ray radiation was used.

alloy. Non-equilibrium solidification condition caused the

formation of an D-Mg phase crystals (depleted in aluminum) and
pushing the aluminum admixture away into interdendritical
spaces. The microstructure consisted of primary D phase (a solid
solution of aluminum in magnesium an D-Mg phase with a
hexagonal closely-packed, hcp structure) and the J-phase (called
also E-phase [2-4]) which is an intermetallic compound with a
stoichiometric composition of Al12Mg17 (at 43.95 wt.% Al) and an
D-Mntype cubic unit cell. The presence of a small amount of
manganese in commercial AM50 magnesium alloy additionally
caused the formation of aluminum-manganese intermetallic
compounds Al8Mn5. The Al8Mn5 intermetallic compound was
found to have also typical polygonal morphology.
It should also be noted that different phases like for example
oxides or iron intermtallic compounds, which consist impurities in
AM50 alloy, were not observed.

Fig. 2. Macrographs of AM50 magnesium alloy centre stack

frame HVAC premium fabricated on the Ital Presse cold chamber
die-casting machine with 1100 tons locking force in the
FINNNVEDEN Metals Structures

3. Results
Castings obtained at the cold chamber die-casting line in the
FINNNVEDEN Metals Structures were characterised by correct
representation of dies without visible casting defects (like
incomplete filling of the die cavity, cold flows or cold shuts, hot
cracking, deformation, distortion or fracture, etc.) and also
satisfactory quality of surfaces (Fig. 2).
Table 1 presents results of chemical composition obtained
from areas marked as X and Y in Fig. 2 in comparison with
ASTM B93-94 standard. Chemical composition of investigated
pressure casting was in agreement with ASTM standard.

Fig. 3. Microstructure of high-pressure die-casting AM50

magnesium alloy (part marked as 1 in Fig. 2); light microscopy

Table 1. Chemical composition of AM50 magnesium alloy

Alloy

Al

Chemical composition [mass.%] *

Mn
Zn
Si
Fe
Cu

according 4.5- 0.28- max max max

max
to ASTM 5.3 0.5 0.02 0.05 0.004 0.008
B93-94
from X1
5.05 0.28 0.049 0.032 0.003
0
from Y1
4.54 0.24 0.049 0.025 0.001 0.0042
* Mg rest
1
areas marked as X and Y in Fig. 2

Ni

Others
each
max
max
0.001 0.01
0
0

0.0066
0.0056

Figs. 3-6 present representative microstructure from parts

marked as 1 and 2 in Fig. 2. They show a typical dendritic
microstructure of a high-pressure die-casting AM50 magnesium

Fig. 4. Microstructure of high-pressure die-casting AM50

magnesium alloy (part marked as 1 in Fig. 2); light microscopy
X-ray phase analysis confirms the presented microstructure
observations. XRD diffraction pattern obtained from investigated
AM50 magnesium alloy casting is presented in Fig. 7. The
presence of D-Mg phase, and J-Al12Mg17 and Al8Mn5
intermetallic compounds was revealed. Additionally, that any
different phases (like impurities) were not disclosed.

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4. Summary
Performed investigations of AM50 magnesium alloy
demonstrate fully satisfy quality of obtained pressure casting.
Chemical composition and phase constitution were typical for
high-pressure die-casting AM50 alloy. Oxides or iron
intermetallic compounds, which constitutes main impurities in
magnesium alloys were not revealed.

Literature:
Fig. 5. Microstructure of high-pressure die-casting AM50
magnesium alloy (part marked as 2 in Fig. 2); light microscopy

Fig. 6. Microstructure of high-pressure die-casting AM50

magnesium alloy (part marked as 2 in Fig. 2); light microscopy

Fig. 8. XRD diffraction pattern of high-pressure die-casting

AM50 magnesium alloy (from part marked as 2 in Fig. 2)

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