MAGSIMAL® 59
AlMg5Si2Mn HPDC ALLOY
Magsimal 59 is an AlMg5Si2Mn aluminium high pressure die casting alloy developed for thin-wall and highly loaded structural components. It combines high yield strength with high ductility, excellent dynamic performance and strong energy absorption in the as-cast condition.
Furthermore, Magsimal® 59 offers excellent corrosion resistance, very good weldability and strong joining performance. Therefore, the alloy is particularly relevant for safety-related automotive and chassis components that must withstand both static and cyclic loads. In addition, its comparatively low density supports lightweight structural design.
HIGH STRENGTH
& DUCTILITY IN HPDC
Magsimal 59 belongs to the Al-Mg-Si family of structural automotive casting alloys. In particular, its magnesium and silicon balance creates a fine Al-Mg2Si eutectic while maintaining useful casting behavior.
As a result, the alloy can achieve demanding mechanical properties directly after casting. Furthermore, the combination of ductility, fatigue resistance and corrosion performance makes it suitable for applications such as cross members, suspension structures, steering components and other safety-relevant castings.
MAGSIMAL 59
CHEMICAL COMPOSITION
The Magsimal 59 chemical composition is based on the AlMg5Si2Mn alloy system. Magnesium represents the dominant alloying addition, while silicon and manganese are controlled within defined ranges.
In particular, the magnesium-to-silicon balance supports the formation of the Al-Mg2Si eutectic. Therefore, chemistry, solidification and mechanical performance are closely connected.
AlMg5Si2Mn
| Range | Si | Fe | Cu | Mn | Mg | Zn | Ti | Be | Others |
|---|---|---|---|---|---|---|---|---|---|
| Minimum | 1.80 | – | – | 0.50 | 5.00 | – | – | – | – |
| Maximum | 2.60 | 0.20 | 0.03 | 0.80 | 6.00 | 0.07 | 0.20 | 0.004 | 0.20 |
Reference manufacturer composition for Magsimal® 59 ingot. Values are expressed as mass percent. Always verify the current alloy specification before production or engineering release.
MAGSIMAL 59
MECHANICAL PROPERTIES
The Magsimal 59 mechanical properties depend strongly on wall thickness and solidification conditions. Therefore, thin structural sections generally provide higher yield strength than thicker cast sections.
Nevertheless, the alloy maintains significant elongation across a broad wall-thickness range. As a result, Magsimal 59 combines strength and ductility in a way that is particularly relevant for dynamically loaded automotive structures.
MAGSIMAL 59 PROPERTY RANGE · F CONDITION
| Wall Thickness | Yield Strength Rp0.2 | Tensile Strength Rm | Elongation A |
|---|---|---|---|
| < 2 mm | > 220 MPa | > 300 MPa | 10–15 % |
| 2–4 mm | 160–220 MPa | 310–340 MPa | 11–22 % |
| 4–6 mm | 140–170 MPa | 250–320 MPa | 9–14 % |
| 6–12 mm | 120–145 MPa | 220–260 MPa | 8–12 % |
WALL THICKNESS
& SOLIDIFICATION
Thin sections cool more rapidly during high pressure die casting. Therefore, local microstructure and mechanical properties are influenced by component geometry and the actual solidification rate.
Consequently, handbook values should not simply be transferred to every location in a production component. Flow path, local solidification, casting quality and specimen position must also be considered during structural validation.
MAGSIMAL 59 FATIGUE
& CORROSION BEHAVIOR
Magsimal 59 fatigue performance is particularly relevant for chassis and safety components exposed to repeated dynamic loading. In addition, the Al-Mg based alloy system provides strong corrosion resistance, including demanding salt-water environments.
HIGH DYNAMIC
LOAD CAPABILITY
Manufacturer testing on 4 mm high pressure die cast plates evaluated Magsimal® 59 under fully reversed cyclic loading in the as-cast condition.
This value applies to the documented material test configuration. Therefore, real components require separate validation for local geometry, surface quality, porosity, casting defects and actual service loading.
EXCELLENT
CORROSION RESISTANCE
Magsimal® 59 belongs to the Al-Mg family of alloys known for high corrosion resistance. Consequently, the material has also been evaluated for applications exposed to salt-water environments.
The documented stress-corrosion evaluation used a 35 g/l NaCl solution while specimens were mechanically loaded. Therefore, corrosion behavior forms an important part of the structural Magsimal 59 material concept.
FATIGUE VALUES ARE COMPONENT-DEPENDENT
Fatigue performance depends not only on alloy chemistry but also on local solidification, casting defects, surface condition and component geometry. Consequently, published laboratory values should be treated as technical reference data rather than universal design limits for production components.
MAGSIMAL 59 HPDC
& AGING BEHAVIOR
Magsimal 59 HPDC processing combines strong as-cast mechanical properties with very good suitability for thin structural sections. Therefore, extensive solution heat treatment is not required to obtain useful structural performance.
However, cooling immediately after casting and subsequent aging can influence yield strength. Consequently, casting process, cooling strategy and required mechanical profile should be considered together.
VERY GOOD
HPDC CASTABILITY
Magsimal® 59 was developed for high pressure die casting and is suitable for demanding thin-wall components. Consequently, complex structural geometries can be produced with high functional integration.
LOW STICKING
TENDENCY
The alloy concept is designed for reduced sticking during high pressure die casting. Nevertheless, correct mold design, melt handling and release-agent strategy remain essential for stable production.
STRONG
AS-CAST STATE
High yield strength and ductility are already available directly after casting. Therefore, the F condition is important for economical structural component production.
ONE-STAGE
TREATMENT
Manufacturer guidance describes an optional one-stage treatment to reduce property differences caused by wall thickness and cooling. In suitable conditions, yield strength can be increased further.
Documented for thin, water-quenched samples after approximately 20 days of room-temperature aging.
Manufacturer testing showed a much smaller natural-aging effect after air cooling.
In the documented aging tests, the increase in yield strength was accompanied by only a small change in elongation.
CASTING + COOLING
+ AGING
Magsimal 59 properties depend on more than the nominal alloy chemistry. Wall thickness, solidification, cooling after ejection and aging history can all influence the final yield strength.
Furthermore, air cooling can reduce distortion compared with more aggressive quenching strategies. Therefore, dimensional stability and mechanical performance should be optimized together rather than evaluated as separate targets.
MAGSIMAL 59 JOINING
& SURFACE ENGINEERING
Magsimal 59 joining performance is important because structural castings are normally integrated into larger vehicle assemblies. Therefore, welding, mechanical joining and adhesive bonding form an important part of the alloy’s application profile.
VERY GOOD
WELDABILITY
RHEINFELDEN describes Magsimal® 59 as very weldable. Therefore, the alloy can be integrated into suitable aluminium profile and cast structural assemblies.
SELF-PIERCING
RIVETING
The alloy is suitable for self-piercing riveting. High local ductility is especially important because significant material deformation occurs around the joining zone.
ADHESIVE
BONDING
Manufacturer documentation identifies Magsimal 59 as highly suitable for adhesive bonding in automotive body structures. Consequently, hybrid joining strategies can combine bonding with mechanical fixation.
MACHINING
& POLISHING
Magsimal® 59 offers good machinability and excellent mechanical polishability. Therefore, functional interfaces and visual surface requirements can be integrated after casting.
JOINING PERFORMANCE IS PART OF STRUCTURAL MATERIAL SELECTION
High tensile values alone do not define a successful structural casting. Welding zones, rivet locations, adhesive surfaces and local deformation must also perform reliably. Consequently, Magsimal 59 combines material strength with joining and manufacturing properties that are particularly relevant for integrated automotive structures.
MAGSIMAL 59
AUTOMOTIVE APPLICATIONS
Magsimal 59 automotive applications focus strongly on components that require a combination of static strength, ductility and resistance to dynamic loading.
Consequently, documented applications include door structures, steering components, cross members and suspension-related castings. Many of these components are used directly in the as-cast state.
SPORTS CAR
DOOR STRUCTURE
A documented Magsimal® 59 door structure demonstrates the ability to combine large component dimensions with a very thin 2 mm wall thickness.
STEERING-WHEEL
FRAME
Manufacturer documentation includes a Magsimal 59 steering-wheel frame for the Volkswagen New Beetle. Therefore, the alloy has been applied to components requiring both low weight and structural reliability.
BMW CROSS
MEMBER
A documented cross member for an off-road vehicle was produced in Magsimal® 59 and identified as weldable. This illustrates the combination of structural casting and downstream joining.
FRONT SUSPENSION
STRUT SUPPORT
The documented BMW 5 and 6 Series suspension support was subjected to very high dynamic loads in the aluminium front structure. Therefore, it represents a particularly relevant Magsimal 59 chassis application.
DOCUMENTED MAGSIMAL 59 APPLICATION LANDSCAPE
MAGSIMAL 59
TECHNICAL FAQ
The following answers summarize key engineering questions regarding Magsimal 59 composition, mechanical properties, HPDC processing, fatigue behavior, corrosion resistance, joining and automotive applications.
What is Magsimal 59?
Magsimal® 59 is an AlMg5Si2Mn aluminium high pressure die casting alloy developed for thin-wall, highly loaded and structural casting applications.
What is the Magsimal 59 alloy designation?
RHEINFELDEN ALLOYS identifies Magsimal® 59 chemically as AlMg5Si2Mn and numerically as material number 51 500.
What are the mechanical properties of Magsimal 59?
Mechanical properties depend on wall thickness. For example, manufacturer data for 2–4 mm sections specifies 160–220 MPa yield strength, 310–340 MPa tensile strength and 11–22 % elongation.
Does Magsimal 59 require heat treatment?
No extensive solution treatment is required to obtain strong structural properties. The alloy already provides high strength and ductility in the as-cast state, although optional aging strategies can further influence yield strength.
Is Magsimal 59 suitable for structural HPDC?
Yes. Documented applications include cross members, suspension structures, steering components, door structures and other dynamically loaded automotive castings.
Is Magsimal 59 weldable?
Yes. Manufacturer documentation describes very good weldability. In addition, the alloy is suitable for self-piercing riveting and adhesive bonding.
What fatigue strength is reported for Magsimal 59?
Manufacturer documentation reports 100 MPa for the referenced as-cast fatigue evaluation using 4 mm HPDC specimens at a stress ratio of R = −1 and 10⁶ cycles.
Is Magsimal 59 corrosion resistant?
Yes. Magsimal® 59 is characterized by RHEINFELDEN ALLOYS as having excellent corrosion resistance, including suitability for demanding salt-water environments.
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