MgAl5Mn (AM 50) and EN-MB MgAl6Mn (AM 60) This alloy is characterized by particularly high elongation and energy absorption …

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4.3 Scattering length

Scattering length is related to radiation length. A foil of 300µm thick Al alreadyhighly affects the performance of the Velo. With 150µm we get a lot closer to theoptimal performance.

4.4 Some material properties

For a table of radiation length/interaction length, see the PDG:http://pdg.lbl.gov/2012/AtomicNuclearProperties/For example:

element density [g/cm3] rad. length [cm] nucl. coll. length [cm] nucl. interact. length [cm]Al 2.7 8.897 25.82 39.70Be 1.85 35.28 29.93 42.10Mg 1.74 14.49 39.20 59.84Ni 8.90 1.42 9.28 15.06Cu 8.96 1.44 9.39 15.32Si 2.33 9.370 30.16 46.52Fe 7.87 1.757 10.37 16.77C(compact) 2.27 18.85 26.14 37.89Zn 7.13 1.74 11.88 19.42

The addition of 1% Mg increases the strength by approximately 10 - 15%. AlMg3contains about 3% Mg. It seems that it only gets stronger if you add more Mg, butthen other problems appear (?). Apparently, you can buy up to 12%. For moreinformation see

http://www.keytometals.com/article75.htmAccording to (page 270)http://www.nist.gov/data/PDFfiles/jpcrd221.pdfthe Matthiessen’s rule for composition of mobility holds quite well for AlMg

alloys. That means that AlMg will not differ very much from pure Al in terms ofconductivity.

With too much Mg (more than 3%) you cannot weld it anymore.Apparently, there also exist strong Al alloys with Mg and Si. You can add up to

20% of Si. However, these allows have poor machinability since Si is hard.Electric conductivity of alloys is usually worse than what you find in tables.The advantage of Wood’s metal is that it conducts temperature well, compared

to wax. However, Herman says that we could as well use wax, since you anywayhave cooling liquid at the right temperature.

4.4.1 Magnesium alloys

An alternative to AlMgX alloys are alloys based on magnesium, rather than Alu-minium as the bulk material. Magnesium is lighter and very easy to machine. It ishowever also more corrosive and burns easily (which is a concern when machining).The following table shows some characteristics of magnesium and aluminium alloys.

3

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The material and its propertiesDiecasting magnesium alloys:

Characteristic physical properties

Magnesium alloys for diecasting make it possible to producecomponents with low weight at competitive manufacturingcosts. Thin walls, dimensional accuracy, short casting cyclesand a long die service life are typical advantages of magne-sium diecastings. Further advantages include the excellentmachinability, good attenuation and (EMI) shielding properties.High purity and advanced corrosion-proofing techniques allowour diecasting alloys to be used in corrosive environments, too.

EN-MB MgAl9Zn1(A) (AZ 91)

The most common diecasting alloy with outstanding castingpro perties and high mechanical strength. Typical applications:automotive parts, computer components, parts for mobilephones, sports equipment, covers and housings, componentsfor chainsaws, manual tools, household appliances, etc.

EN-MB MgAl5Mn (AM 50) and EN-MB MgAl6Mn (AM 60)

This alloy is characterized by particularly high elongation andenergy absorption with high mechanical strength and goodcasting properties. Typical applications are to be found inautomotive engineering: seat frames, steering wheels, dash-board supports, fanwheels, etc.

EN-MB MgAl2Mn (AM 20)

High elongation combined with high impact strength is char-acteristic of this alloy. It is therefore typically used for safetycomponents in motor vehicles.

Characteristic mechanical properties (at room temperature)The values apply for test bars cast separately

Alloy % Al % Mn % Zn % Si % Cu % Ni % Fe Others (max) (max) (max) (max) (max) max % each

EN-MB MgAl9Zn1(A) EN-MB 21120 8.5-9.5 min. 0.17 0.45-0.90 0.05 0.025 0.001 0.004 0.01

EN-MB MgAl6Mn EN-MB 21230 5.6-6.4 min. 0.23 max. 0.20 0.05 0.008 0.001 0.004 0.01

EN-MB MgAl5Mn EN-MB 21220 4.5-5.3 min. 0.27 max. 0.20 0.05 0.008 0.001 0.004 0.01

EN-MB MgAl2Mn EN-MB 21210 1.7-2.5 min. 0.35 max. 0.20 0.05 0.008 0.001 0.004 0.01

Diecast parts

Properties Unit EN-MC MgAl9Zn1(A) EN-MC MgAl6Mn EN-MC MgAl5Mn EN-MC MgAl2Mn (AZ 91) (AM 60) (AM 50) (AM 20)

Tensile strength N/mm2 200 - 260 190 - 250 180 - 230 150 - 220

0.2 % proof stress N/mm2 140 - 170 120 - 150 110 - 130 80 - 100

Compression strength N/mm2 148 nm 113 74

Elongation at rupture % 1 - 6 4 - 14 5 - 15 8 - 18

Modulus of elasticity kN/mm2 45 45 45 45

Shear modulus kN/mm2 17 nm nm nm

Brinell hardness HBS 1/5 65 - 85 55 - 70 50 - 65 40 - 55

Impact strength acc. to J 6 17 18 18Charpy, without notch

nm: not measured

The mechanica l properties of an a lloy depend very large ly on the production method used and its variables.

Properties Unit Temp.°C EN-MC MgAl9Zn1(A) EN-MC MgAl6Mn EN-MC MgAl5Mn EN-MC MgAl2Mn (AZ 91) (AM 60) (AM 50) (AM 20)

Density g/cm3 20 1.81 1.80 1.77 1.75

Liquidus temperature °C 598 615 620 638

Initial melting temperature °C 420-435 420-435 420-435 420-435

Coefficient of thermal expansion µm/m·K 20-100 26.0 26.0 26.0 26.0

Heat of fusion kJ/kg 370 370 370 370

Spec. thermal capacity kJ/kg·K 20 1.02 1.02 1.02 1.02

Thermal conductivity W/K·m 20 51 61 65 94

Electrical conductivity MS/m 20 6.6 nm 9.1 13.1

nm: not measured

The information and spec ifications can be found in: DIN EN 1753 and ASTM standards.STIHL cannot accept any warranty or liability for the information conta ined in this brochure , which has been compiled to the best of our know ledge and be lief. Subject to printing errors.

Alloy % Al % Mn % Zn % Si % Cu % Ni % Fe Others(max) (max) (max) (max) (max) max % each

EN-MC MgAl9Zn1(A) EN-MC 21120 8.3-9.7 min 0.10 0.35-1.00 0.10 0.030 0.002 0.005 0.01

EN-MC MgAl6Mn EN-MC 21230 5.5-6.5 min 0.10 max. 0.20 0.10 0.010 0.002 0.005 0.01

EN-MC MgAl5Mn EN-MC 21220 4.4-5.5 min 0.10 max. 0.20 0.10 0.010 0.002 0.005 0.01

EN-MC MgAl2Mn EN-MC 21210 1.6-2.6 min 0.10 max. 0.20 0.10 0.010 0.002 0.005 0.01

Composition of pigs for diecasting magnesium

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The material and its propertiesDiecasting magnesium alloys:

Characteristic physical properties

Magnesium alloys for diecasting make it possible to producecomponents with low weight at competitive manufacturingcosts. Thin walls, dimensional accuracy, short casting cyclesand a long die service life are typical advantages of magne-sium diecastings. Further advantages include the excellentmachinability, good attenuation and (EMI) shielding properties.High purity and advanced corrosion-proofing techniques allowour diecasting alloys to be used in corrosive environments, too.

EN-MB MgAl9Zn1(A) (AZ 91)

The most common diecasting alloy with outstanding castingpro perties and high mechanical strength. Typical applications:automotive parts, computer components, parts for mobilephones, sports equipment, covers and housings, componentsfor chainsaws, manual tools, household appliances, etc.

EN-MB MgAl5Mn (AM 50) and EN-MB MgAl6Mn (AM 60)

This alloy is characterized by particularly high elongation andenergy absorption with high mechanical strength and goodcasting properties. Typical applications are to be found inautomotive engineering: seat frames, steering wheels, dash-board supports, fanwheels, etc.

EN-MB MgAl2Mn (AM 20)

High elongation combined with high impact strength is char-acteristic of this alloy. It is therefore typically used for safetycomponents in motor vehicles.

Characteristic mechanical properties (at room temperature)The values apply for test bars cast separately

Alloy % Al % Mn % Zn % Si % Cu % Ni % Fe Others (max) (max) (max) (max) (max) max % each

EN-MB MgAl9Zn1(A) EN-MB 21120 8.5-9.5 min. 0.17 0.45-0.90 0.05 0.025 0.001 0.004 0.01

EN-MB MgAl6Mn EN-MB 21230 5.6-6.4 min. 0.23 max. 0.20 0.05 0.008 0.001 0.004 0.01

EN-MB MgAl5Mn EN-MB 21220 4.5-5.3 min. 0.27 max. 0.20 0.05 0.008 0.001 0.004 0.01

EN-MB MgAl2Mn EN-MB 21210 1.7-2.5 min. 0.35 max. 0.20 0.05 0.008 0.001 0.004 0.01

Diecast parts

Properties Unit EN-MC MgAl9Zn1(A) EN-MC MgAl6Mn EN-MC MgAl5Mn EN-MC MgAl2Mn (AZ 91) (AM 60) (AM 50) (AM 20)

Tensile strength N/mm2 200 - 260 190 - 250 180 - 230 150 - 220

0.2 % proof stress N/mm2 140 - 170 120 - 150 110 - 130 80 - 100

Compression strength N/mm2 148 nm 113 74

Elongation at rupture % 1 - 6 4 - 14 5 - 15 8 - 18

Modulus of elasticity kN/mm2 45 45 45 45

Shear modulus kN/mm2 17 nm nm nm

Brinell hardness HBS 1/5 65 - 85 55 - 70 50 - 65 40 - 55

Impact strength acc. to J 6 17 18 18Charpy, without notch

nm: not measured

The mechanica l properties of an a lloy depend very large ly on the production method used and its variables.

Properties Unit Temp.°C EN-MC MgAl9Zn1(A) EN-MC MgAl6Mn EN-MC MgAl5Mn EN-MC MgAl2Mn (AZ 91) (AM 60) (AM 50) (AM 20)

Density g/cm3 20 1.81 1.80 1.77 1.75

Liquidus temperature °C 598 615 620 638

Initial melting temperature °C 420-435 420-435 420-435 420-435

Coefficient of thermal expansion µm/m·K 20-100 26.0 26.0 26.0 26.0

Heat of fusion kJ/kg 370 370 370 370

Spec. thermal capacity kJ/kg·K 20 1.02 1.02 1.02 1.02

Thermal conductivity W/K·m 20 51 61 65 94

Electrical conductivity MS/m 20 6.6 nm 9.1 13.1

nm: not measured

The information and spec ifications can be found in: DIN EN 1753 and ASTM standards.STIHL cannot accept any warranty or liability for the information conta ined in this brochure , which has been compiled to the best of our know ledge and be lief. Subject to printing errors.

Alloy % Al % Mn % Zn % Si % Cu % Ni % Fe Others(max) (max) (max) (max) (max) max % each

EN-MC MgAl9Zn1(A) EN-MC 21120 8.3-9.7 min 0.10 0.35-1.00 0.10 0.030 0.002 0.005 0.01

EN-MC MgAl6Mn EN-MC 21230 5.5-6.5 min 0.10 max. 0.20 0.10 0.010 0.002 0.005 0.01

EN-MC MgAl5Mn EN-MC 21220 4.4-5.5 min 0.10 max. 0.20 0.10 0.010 0.002 0.005 0.01

EN-MC MgAl2Mn EN-MC 21210 1.6-2.6 min 0.10 max. 0.20 0.10 0.010 0.002 0.005 0.01

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Conventional Die-Casting

Magnesium Injection Molding

Cold Chamber Hot Chamber

Capability OptionsPhillips-Medisize’s magnesium injection mold-ing capabilities include: conventional single shot, overmolding with plastic, and insert molding. Insert molding metals into magnesium alloys can be accomplished with almost any type of insert, including dissimilar metals, as long as the insert does not have a lesser melting point than the alloy. Complexity and part design are considerations with regards to part cost. Hinges and tongue and groove features (popular when considering a plastic part with a magnesium part for rigidity characteristics) are all items that can be incorporated into the product design and easily molded into the parts. Additionally, these designs can help eliminate visible parting lines on critical surfaces.

Assembly ConsiderationsPhillips-Medisize’s in-depth knowledge of the entire manufacturing process, combined with its assem-bly services, provides customers with true turnkey capabilities. Phillips-Medisize provides customers an unparalleled range of assembly services, which in-cludes: component design, design for manufacture, and quotes for assembly and finishing operations.

Metallurgical LabPhillips-Medisize’s in-house metallurgical lab is an integral part of the Thixomolding® process with people exclusively trained to perform microstructure studies on materials. This lab gives Phillips-Medisize the capability to fully monitor and analyze materi-als, and aids in the development of the magnesium injection process.

Environmental Considerations

Magnesium injection molding is an environ-

mentally 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

earth’s surface and can be safely manufac-

tured in a low hazard environment.

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