Magnesium ZK61A-T5, Cast，UNS M16611; Mg; AMS 4444; ASTM B 80; SAE J465; Old SAE 513 (Ingot UNS M16610),E FOUR

### **Product Datasheet: Magnesium ZK61A-T5, Cast (UNS M16611)** **Premium High-Strength Sand Casting Magnesium Alloy** --- #### **1. Overview** Magnesium ZK61A-T5 (UNS M16611) is a premium high-strength sand casting alloy that achieves exceptional mechanical properties through optimized zinc content, zirconium grain refinement, and T5 artificial aging treatment. Conforming to AMS 4444, ASTM B80, and SAE J465 specifications, this alloy represents one of the highest strength magnesium casting materials available. The carefully controlled composition and heat treatment produce castings with reliable performance characteristics suitable for the most demanding aerospace and defense applications. --- #### **2. Key Features & Advantages** - **Exceptional Strength-to-Weight Ratio:** Highest strength among magnesium casting alloys - **Superior Castability:** Excellent fluidity and feeding characteristics - **Fine Grain Structure:** Zirconium provides effective grain refinement - **Enhanced Mechanical Properties:** T5 treatment optimizes strength and ductility - **Good Corrosion Resistance:** Meets aerospace environmental requirements - **Pressure Tight:** Suitable for hydraulic and pneumatic applications - **Proven Reliability:** Extensive history in critical aerospace components --- #### **3. Chemical Composition (Weight %)** As specified in AMS 4444, ASTM B80, and SAE J465: | Element | Magnesium (Balance) | Zinc | Zirconium | Manganese (max) | Silicon (max) | Other Elements (max) | |---------------|---------------------|--------------|--------------|-----------------|---------------|---------------------| | **Content (%)** | - | 5.5-6.5 | 0.45-1.0 | 0.15 | 0.10 | 0.30 total | *Ingot Designation: UNS M16610* *Old SAE Designation: SAE 513 (Superseded)* *Note: The high zinc content provides maximum solid solution strengthening potential, while zirconium ensures fine, uniform grain structure throughout the casting, creating optimal conditions for T5 aging response and mechanical properties.* --- #### **4. Typical Physical & Mechanical Properties (T5 Temper)** **Physical Properties:** | Property | Value | |---------------------------|------------------------------| | **Density** | 1.83 g/cm³ (0.0661 lb/in³) | | **Melting Range** | 515-630°C (959-1166°F) | | **Thermal Conductivity** | 111 W/m·K | | **Specific Heat Capacity**| 1005 J/kg·K | | **Coefficient of Thermal Expansion** | 25.4 × 10⁻⁶/°C | | **Solidification Shrinkage** | 4.1% | **Mechanical Properties (Sand Cast - T5 Temper):** | Property | Minimum | Typical | |---------------------------|----------------|----------------| | **Ultimate Tensile Strength** | 280 MPa (41 ksi) | 310 MPa (45 ksi) | | **Tensile Yield Strength**| 185 MPa (27 ksi) | 215 MPa (31 ksi) | | **Elongation** | 5% | 8% | | **Compressive Yield Strength** | 185 MPa (27 ksi) | 215 MPa (31 ksi) | | **Shear Strength** | 165 MPa (24 ksi) | 190 MPa (28 ksi) | | **Fatigue Strength** | 115 MPa (17 ksi) | 135 MPa (20 ksi) | | **Elastic Modulus** | 45 GPa (6.5×10⁶ psi) | 45 GPa (6.5×10⁶ psi) | | **Hardness** | 70 HB | 80 HB | | **Impact Toughness** | 4 J | 6 J | | **Bearing Strength** | 500 MPa (73 ksi) | 550 MPa (80 ksi) | | **Bearing Yield Strength**| 360 MPa (52 ksi) | 400 MPa (58 ksi) | --- #### **5. International Standards & Specifications** ZK61A-T5 Castings fully comply with: - **AMS 4444:** Aerospace Material Specification for Sand Castings - **ASTM B80:** Standard Specification for Magnesium-Alloy Sand Castings - **SAE J465:** Wrought and Cast Magnesium Alloys - **UNS M16611:** Cast Products Designation - **UNS M16610:** Ingot Designation - **Old SAE 513:** Previous Designation (Superseded) --- #### **6. Applications** **Aerospace & Defense:** - Aircraft transmission housings and gearboxes - Helicopter transmission casings and components - Missile body sections and structural members - Engine accessory mounts and brackets - Wing root fittings and structural attachments - Satellite structural components and housings **Military Applications:** - Weapon system structural components - Military vehicle transmission cases - Portable equipment structural housings - Radar antenna bases and supports **High-Performance Automotive:** - Racing transmission cases and components - High-performance engine parts - Sports car structural components - Motorcycle engine and transmission cases **Industrial Equipment:** - High-speed compressor housings - Pump bodies and pressure housings - Machinery structural components - Robotics structural parts --- #### **7. Foundry & Processing Parameters** **Casting Characteristics:** - **Pouring Temperature:** 710-760°C (1310-1400°F) - **Mold Temperature:** 200-400°C (392-752°F) - **Fluidity:** Excellent for complex castings - **Feeding Requirements:** Moderate to high - **Hot Tearing Tendency:** Low with proper design **Heat Treatment (T5):** - **Artificial Aging:** 150-175°C (302-347°F) for 16-24 hours - **Temperature Control:** ±3°C (±5°F) for aerospace quality - **Cooling:** Air cool to room temperature - **Atmosphere:** Air atmosphere acceptable **Machining Characteristics:** - **Machinability Rating:** Excellent - **Cutting Speed:** High-speed operations possible - **Surface Finish:** 0.8-1.6 μm Ra achievable - **Tool Life:** Extended compared to steel machining **Quality Control Requirements:** - **Chemical Analysis:** Required for heat certification - **Mechanical Testing:** Tensile testing from separately cast coupons - **Radiographic Inspection:** Per applicable quality levels - **Dye Penetrant:** For surface defect detection - **Microstructural Examination:** Grain size verification --- #### **8. Design & Manufacturing Considerations** - **Section Thickness:** 4-75 mm recommended - **Draft Angles:** 1-3° typically required - **Fillet Radii:** Minimum 4 mm for stress reduction - **Coring:** Accommodates complex core configurations - **Machining Allowances:** 2.0-4.0 mm typical - **Quality Documentation:** Full traceability for aerospace applications --- **Disclaimer** This technical data is based on industry standards and typical foundry experience. Properties may vary depending on casting design, section size, and specific processing parameters. Users should consult the latest revisions of AMS 4444, ASTM B80, and SAE J465 specifications for current requirements. All manufacturing processes must follow established safety procedures for magnesium casting and machining operations. ZK61A-T5 represents a premium high-strength magnesium casting alloy suitable for the most demanding applications where maximum performance is required.

Packing of Standard Packing: Typical bulk packaging includes palletized plastic 5 gallon/25 kg. pails, fiber and steel drums to 1 ton super sacks in full container (FCL) or truck load (T/L) quantities. Research and sample quantities and hygroscopic, oxidizing or other air sensitive materials may be packaged under argon or vacuum. Solutions are packaged in polypropylene, plastic or glass jars up to palletized 3377 gallon liquid totes Special package is available on request.