A380 casting alloy
Identity, process and qualification boundaries for A380 aluminium die castings, chemistry, porosity and finishing.
Tags: materials, aluminum, die-casting, casting-alloys
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Identify the complete alloy and casting route
The Aluminum Association's August 2025 Pink Sheets distinguish A380.0 die castings from A380.1 and A380.2 ingot. The A380.0 entry specifies 7.5–9.5% silicon and 3.0–4.0% copper by mass, among other limits. Link the charge-metal record to the finished-casting lot when verifying the order. AA casting and ingot registrations
A380 is a widely used aluminium die-casting alloy designation. Dynacast lists it among its aluminium casting alloys and associates A380 with cold-chamber die casting in its material selector. Treat the designation as one input to a casting specification, not a guarantee of finished-part strength, pressure tightness, dimensions or surface appearance. Dynacast aluminium alloys, Dynacast material selector
Casting chemistry is distinct from ingot identity
The Aluminum Association's Pink Sheets, revised August 2025, register A380.0 as a die-casting alloy. Selected limits are 7.5–9.5% silicon and 3.0–4.0% copper by mass, with maxima including 1.3% iron, 0.50% manganese, 0.10% magnesium, 0.50% nickel and 3.0% zinc. Aluminium is the remainder subject to the other-element provisions. These ranges identify chemistry; they are not the measured analysis of each melt. AA Pink Sheets, A380.0 entry
For receiving and traceability, connect charge-metal documentation, melt control and finished-casting lot identification. A material-family declaration cannot establish a specific casting's internal integrity or compliance with the drawing.
Product specification and property data
ASTM B85/B85M-25 is a specification for aluminium-alloy die castings in general-purpose applications. Its public scope expressly warns that it may not address the mechanical properties, integrity testing and verification needed for highly loaded or safety-critical applications. Define those additional requirements with the producer rather than assuming the alloy name or standard citation covers them. ASTM B85/B85M scope
Separate the roles of chemistry limits, representative mechanical data, acceptance requirements and design allowables. Before using a strength or elongation value, identify whether it comes from a separately cast specimen or a specimen removed from a production casting, and preserve process, condition, section thickness and location. A number without that basis is incomplete design information.
NADCA's research program explicitly addresses properties versus section thickness using specimens cut from production castings. This illustrates why local wall thickness and casting history matter; it is not a new property guarantee for an A380 part. Use an agreed casting-specific verification plan where structural performance is required. NADCA project 211, properties versus section thickness
Do not assume a generic T6 cycle, post-casting heating operation or weld repair preserves the original qualified condition. Obtain process-specific agreement on permitted thermal operations and repairs, then verify the required dimensions and properties afterward. This page supplies no universal heat-treatment or repair procedure.
Porosity, geometry and machining
Dynacast distinguishes gas porosity, associated with trapped air, from shrinkage porosity, associated with solidification. It describes flow analysis, venting, thermal management and geometry changes as ways to address them. The controls belong to the part/tool/process combination, not to chemistry alone. Dynacast die-casting design FAQ
Review wall transitions, bosses, ribs, gates, overflows, ejector locations and the intended parting line with the caster. Nominally uniform walls can still produce difficult local features. A general minimum-wall or tolerance claim should not replace an assessment of the actual fill, solidification and ejection conditions.
Plan machined sealing faces, bores and threads before tooling release. Define machining allowance and the inspection stage: acceptance of an as-cast surface does not prove the condition of material exposed after machining. Where a feature seals a fluid path, qualify the completed machined and assembled condition.
Dynacast's quality-assurance discussion specifically identifies porosity as critical for parts with leak-tight requirements. Specify test medium, pressure, temperature, allowable leakage, fixture and test stage for the application. If impregnation or another remedial process is permitted, identify it explicitly and retain traceability; do not silently redefine a failed casting as acceptable. Dynacast porosity and leak-quality context
Finish and service are separate qualifications
A surface-treatment route needs its own requirements: preparation, coating system, coverage, cosmetic criteria and the test conditions used to demonstrate performance. Dynacast's surface-finish guidance uses 380 aluminium as an example where a protective conversion treatment or anodising may be considered. That general example does not establish a specific A380 coating, decorative colour or corrosion-life guarantee. Dynacast surface-finish selection
Consider actual fluids, temperature, moisture traps, dissimilar-metal contacts and loading. A housing application does not establish pressure-vessel suitability; a successful salt-spray result does not establish service life. Likewise, a visually sound casting does not prove fatigue performance or internal soundness.
For a useful qualification record, retain alloy/melt and casting-lot identity, cavity/tool revision, controlled process, permitted porosity/defect criteria, machining and finishing route, dimensional results and functional tests. Keep changes to alloy source, tool, process, repair or coating visible for assessment against the accepted part.
Sources were reviewed November 1, 2026. The Pink Sheets date is taken from the printed August 2025 revision; the October upload path and search dates are not treated as publication revisions.