Custom Magnesium Alloy Components 

Aikerly Magnesium Alloy Component Manufacturing Processes

Manufacturing Processes for Custom Magnesium Alloy Components

Magnesium alloy components require different forming methods depending on the alloy, component geometry, wall thickness, mechanical requirements, and production quantity.

Aikerly works with manufacturing resources in China covering casting, die casting, semi-solid forming, extrusion, forging, rolling, machining, and secondary processing. We select the manufacturing route according to the actual component rather than applying the same process to every part.

The objective is simple: use the appropriate magnesium alloy and process to produce the required component with controlled quality and cost.

Casting

Casting is suitable for magnesium alloy components with complex geometries, integrated features, variable wall thicknesses, or shapes that are difficult to produce by plastic forming.

Gravity Casting

Gravity casting uses the natural flow of molten magnesium alloy into a mold.

It is suitable for:

• Prototype and development parts

• Low to medium production quantities

• Larger or relatively complex components

• Components where flexible tooling is important

Gravity casting can be combined with machining and surface treatment to produce finished magnesium alloy components.

Low-Pressure Casting

Low-pressure casting uses controlled pressure to fill the mold with molten magnesium alloy.

Compared with conventional gravity casting, the controlled filling process can provide better control of metal flow and reduce certain casting defects.

It can be considered for structural and relatively complex magnesium alloy components where casting integrity is important.

High-Pressure Die Casting

High-pressure die casting is widely used for magnesium alloy components with complex shapes, thin walls, integrated features, and relatively high production requirements.

The process can produce:

• Electronic equipment housings

• Tool and equipment housings

• Automotive brackets and structural components

• Instrument and equipment components

• Lightweight integrated components

For die-cast components, alloy selection, wall thickness, filling behavior, mold design, cooling, and subsequent machining all affect the final result.

Aikerly evaluates these factors together when selecting a die-casting route.

Semi-Solid Forming

Semi-solid forming processes magnesium alloy in a state between liquid and solid.

The material has controlled solid and liquid phases, allowing it to flow into complex cavities while maintaining characteristics different from conventional liquid casting.

Rheocasting

Rheocasting prepares a semi-solid magnesium alloy slurry and then forms it in a mold.

The process can be considered for complex components where improved filling control and component integrity are required.

Thixomolding

Thixomolding is a representative semi-solid injection process for magnesium alloys.

Magnesium alloy feedstock is heated to a semi-solid state and injected into a mold under controlled conditions.

It is suitable for:

• Thin-wall housings

• Precision electronic components

• Small and medium magnesium alloy components

• Components requiring complex integrated features

Semi-solid forming is particularly useful when a component requires a combination of complex geometry, thin walls, dimensional control, and good material integrity.

Extrusion

Extrusion is one of the most practical processes for wrought magnesium alloys.

A heated magnesium alloy billet is forced through a die to produce a continuous profile.

It is suitable for:

• Bars

• Tubes

• Profiles

• Frames

• Rails

• Structural sections

• Custom cross-section components

Extrusion is especially useful when the component has a constant or controlled cross-section along its length.

Aikerly can coordinate custom extrusion profiles and subsequent operations such as cutting, CNC machining, drilling, tapping, bending, and surface treatment.

For custom components, extrusion can often reduce machining volume compared with manufacturing the entire part from solid stock.

Forging

Forging forms magnesium alloy through controlled plastic deformation under compressive force.

It is used when the component requires a combination of low weight, structural integrity, and mechanical performance.

Typical applications include:

• Structural brackets

• Mechanical components

• Load-bearing components

• Aerospace-related lightweight parts

• High-performance equipment components

Hot forging and controlled-temperature forging are commonly used because magnesium alloys have limited plasticity at room temperature.

The alloy condition, forging temperature, deformation rate, die design, and deformation direction must be matched to the component.

Rolling

Rolling is primarily used to produce magnesium alloy sheet and strip.

Because magnesium alloys have a hexagonal close-packed crystal structure, temperature and rolling conditions have a significant influence on formability.

Rolled magnesium sheet can be used for:

• Housings

• Covers

• Panels

• Lightweight structural parts

• Formed sheet components

Where necessary, rolled sheet can be combined with stamping, bending, machining, and other secondary operations to produce the final component.

Warm Forming and Sheet Forming

Many magnesium alloys are difficult to form at room temperature.

Controlled-temperature forming can significantly improve their formability.

Depending on the alloy and geometry, processes may include:

• Warm stamping

• Warm bending

• Warm drawing

• Hot forming

• Isothermal forming

These processes are considered when a sheet component has a shape that cannot be reliably produced by cold forming.

Temperature control is particularly important for magnesium alloy sheet because it directly affects plasticity, forming force, cracking risk, and final dimensions.

CNC Machining

Machining is often an important part of magnesium alloy component manufacturing.

CNC milling, turning, drilling, tapping, and other machining operations can be used after casting, extrusion, forging, or from magnesium alloy stock.

Machining is suitable for:

• Precision mounting surfaces

• Holes and threads

• Complex local features

• Tight-tolerance dimensions

• Prototype and low-volume components

• Final dimensional correction after forming

Magnesium alloys require appropriate machining parameters, tooling, chip control, and safety measures because of their flammability during machining.

Aikerly coordinates machining conditions according to the alloy and component geometry rather than treating magnesium as a conventional aluminum material.

Surface Treatment

Magnesium alloys require appropriate surface protection for many applications.

Depending on the component and operating environment, available treatments may include:

• Conversion coatings

• Anodizing

• Painting

• Powder coating

• Plating

• Other corrosion-protection systems

Surface treatment is selected together with the alloy, manufacturing process, dimensional requirements, appearance, and service environment.

For components with tight dimensional tolerances, the coating thickness must also be considered during engineering review.

Additive Manufacturing

Additive manufacturing of magnesium alloys is developing rapidly, particularly for specialized components and development work.

Processes such as laser powder bed fusion (LPBF) and directed energy deposition (DED) can produce geometries that are difficult to manufacture using conventional methods.

They can be considered for:

• Complex prototypes

• Customized components

• Small quantities

• Research and development parts

• Components with internal structures that are difficult to machine or cast

Because magnesium alloys are highly reactive during melting and have a relatively narrow processing window, additive manufacturing requires specialized equipment and process control.

For most conventional magnesium alloy components, Aikerly first evaluates casting, extrusion, forging, or machining before considering additive manufacturing.

Selecting the Manufacturing Process

There is no single best magnesium alloy manufacturing process.

The right process depends on the actual component.

A simple way to look at it is:

Complex housing or integrated structure → Die casting / semi-solid forming

Constant-section profile → Extrusion

High-performance structural component → Forging

Sheet component → Rolling + warm forming

Prototype or low-volume precision part → CNC machining / casting

Highly complex customized geometry → Additive manufacturing may be considered

The alloy also matters. A process suitable for AZ31B may not be suitable for AZ91D, and a wrought alloy should not automatically be treated like a die-casting alloy.

How Aikerly Makes Custom Magnesium Alloy Components

Aikerly does not simply assign a drawing to a factory.

We first look at the alloy, component structure, manufacturing process, tolerance, quantity, surface requirements, and intended application.

We then select the appropriate production route and coordinate the required manufacturing resources in China.

A component may require more than one process.

For example, an extruded magnesium profile may be extruded first, cut to length, CNC machined, drilled and tapped, and then surface treated.

A die-cast housing may require die casting, trimming, CNC machining, inspection, and surface treatment.

The manufacturing process is therefore determined by the component itself.

Send us your drawing or component requirements. Aikerly can review the part and determine a practical magnesium alloy, forming process, machining route, and production method.