As a die-casting supplier, we build millions of thin-wall housings from A380 because it balances fluidity, strength, dimensional stability and cost. This guide explains A380 in plain English—with the numbers design engineers and buyers actually need.
What is A380 aluminum?
A380 is a high-silicon, copper-bearing aluminum die-casting alloy. It fills very thin sections, resists hot tearing, machines cleanly, and delivers reliable strength for structural covers, housings and brackets.
Why people choose it
- Fills 1.5–3.0 mm walls and complex ribs/bosses with fewer cold shuts.
- Strength around UTS ~ 320–330 MPa, YS ~ 150–165 MPa (as-cast, typical).
- Good pressure tightness with vacuum die casting.
- Stable dimensions and good surface for powder coating or e-coat.
- Lower cost than machining from wrought 6061/6063 blocks.
What is the chemical composition of A380?
Typical specification ranges (wt.%). Exact limits vary by standard (ASTM/EN/JIS); your PO/print governs.
| Element | Range (wt.%) |
|---|---|
| Silicon (Si) | 7.5–9.5 |
| Copper (Cu) | 2.0–3.5 |
| Iron (Fe) | ≤ 1.3 |
| Manganese (Mn) | ≤ 0.5 |
| Magnesium (Mg) | ≤ 0.1 |
| Nickel (Ni) | ≤ 0.5 |
| Zinc (Zn) | ≤ 3.0 |
| Tin (Sn) | ≤ 0.35 |
| Others (each/total) | ≤ 0.05 / ≤ 0.15 |
| Aluminum | Balance |
What the chemistry does
- Si gives fluidity and low shrinkage → thin walls and crisp details.
- Cu lifts strength/hardness but can reduce corrosion resistance—plan coatings.
- Fe/Mn/Ni help control soldering and hot-cracking behavior in the die.
What are A380 mechanical and physical properties?
oom-temperature as-cast values (guidance—actual results depend on gate design, vacuum, wall thickness, and cooling).
| Property | Typical value |
|---|---|
| Ultimate tensile strength (UTS) | ~324 MPa |
| Yield strength (0.2% offset) | ~150–165 MPa |
| Elongation (50 mm) | ~3–4 % |
| Brinell hardness | ~80 HB |
| Density | ~2.71 g/cm³ |
| Thermal conductivity | ~90–105 W/m·K |
| Electrical conductivity | ~23 % IACS |
| Coefficient of thermal expansion | ~21–23 µm/m·K |
Tip: Properties are thickness-sensitive. A 2.5 mm wall that cools quickly will outperform a 6 mm wall that cools slowly.
How does A380 compare with A360, A383/ADC12 and 6061?
| Alloy | When to choose it | Strength/ductility | Fluidity & thin-wall | Corrosion | Notes |
|---|---|---|---|---|---|
| A380 | Best all-around for housings/brackets | UTS ~320–330 MPa, elong ~3–4% | Excellent | Needs coating in harsh environments | Global availability; lowest total cost |
| A360 | Pressure-tight parts, better corrosion | Similar UTS, slightly higher elong | Very good | Better than A380 | A bit harder to cast; cost ↑ |
| A383 / ADC12 | Very complex, ultra-thin geometries | Slightly lower strength than A380 | Best filling of the three | Similar to A380 | Japan/Asia standard; great castability |
| 6061 (wrought) | Machined billet/forgings | Much higher elongation after heat-treat | N/A | Good without coating | Not a die-casting alloy; costly if cut from plate |
Rule of thumb
- Tightness & corrosion first? Try A360.
- Extreme thin-wall fill? Try A383/ADC12.
- Balanced cost + strength + flow? Stay with A380.
Which standards and near-equivalents match A380?
| System | Common designation |
|---|---|
| North America (AA/ASTM) | A380.0 |
| Japan (JIS) | ADC10 / ADC12 (ADC12 is closer to A383, often used as a substitute based on supply) |
| China (GB) | YlSi9Cu3 (varies by foundry) |
| Europe (EN AC) | EN AC-46000 (AlSi9Cu3) / EN AC-46500 (range overlaps A380) |
Always confirm chemistry + properties on the print before cross-substitution.
How do you cast A380 successfully?
Melt & die temperatures
- Melt: 660–690 °C (keep oxides down, avoid overheat).
- Die: 180–220 °C (thinner walls → warmer die to keep flow).
Gating & speed
- Gate velocity: 45–60 m/s for thin-wall housings.
- Fill time: < 0.10 s on 2–3 mm sections to avoid cold shuts.
Vacuum
- Part-ing vacuum ≤ 25 mbar typical for pressure-tight housings; degas melt (rotary impeller or tablets).
Lubrication & release
- Apply uniform die lube; avoid puddling (porosity source).
Dimensional control
- Balance ejector layout; add 0.3–0.5 mm machining allowance on gasket faces and bearing bores.
Which surface finishes work best on A380 die castings?
| Finish | Why it’s used | Notes |
|---|---|---|
| Powder coating | Durable cosmetics and corrosion protection | Bead blast 120–180 grit Al₂O₃ first; phosphate or zirconium conversion; pre-bake thick parts to vent volatiles |
| E-coat | Uniform thin film, great for appliances/automotive | Excellent coverage; masking needed for grounds/pads |
| Conversion coat (chromate/zirconium) | Conductive base layer under paint | Use when electrical bonding/EMI grounding is needed |
| Anodizing | Limited, for basic cosmetic tint | High Si makes conventional clear anodize gray; manage expectations or choose paint/powder |
How do you prevent common A380 casting defects?
| Defect | Root cause | Prevention |
|---|---|---|
| Porosity (gas/shrink) | Trapped air, poor venting, long fill, hot spots | Pull ≤ 25 mbar vacuum, fast fill, add chill & riser pads, thicken local wall or add rib to move heat |
| Cold shuts/lack of fusion | Metal front freezes before meeting | Raise die temp, shorten fill time, redesign gate to impinge fronts |
| Soldering to die | Poor lube or iron pickup | Maintain Fe window, polish steel, correct lube concentration/cycle |
| Warp/flatness | Uneven ejection or cooling | Balance ejectors, stabilize die temperature, design ribs symmetrically |
| Coating pinholes/outgassing | Entrapped volatiles | Pre-bake before powder; choose slower cure schedule |
Where is A380 aluminum used?
A380’s combination of castability, strength, and cost makes it the default alloy for high-volume, thin-wall housings and brackets. Below are common industries, typical parts, why A380 is chosen, and finishing notes you can copy into drawings and RFQs.
Automotive & EV powertrain
- Typical parts: Motor/inverter housings, transmission cases, valve bodies, oil pump covers, bracketry, e-compressor shells.
- Why A380: Excellent flow for 1.5–3.0 mm walls, robust UTS ~324 MPa, stable dimensions for gasket faces.
- Specs & notes: Pressure-tightness to ≤ 10–30 mbar/min depending on cavity; flatness ≤ 0.15 mm/100 mm typical after rough skim; powder coat + zinc-phosphate/zirconium pretreat.
Industrial power & machinery
- Typical parts: Gearbox covers, hydraulic manifolds, pump and compressor endplates, machine guards.
- Why A380: Good machinability; complex internal features via sliders/cores; cost-effective vs. hog-out 6061.
- Specs & notes: Bead blast 120–180 grit Al₂O₃ then coat; add 0.3–0.5 mm stock for post-machining.
HVAC & appliances
- Typical parts: Compressor housings, blower frames, motor end bells, control enclosures.
- Why A380: Thermal conductivity ~96 W/m·K adequate for heat spreading; stable cosmetics with e-coat.
- Specs & notes: E-coat or powder preferred; pre-bake to prevent outgassing on thick ribs/bosses.
Electronics, telecom & lighting
- Typical parts: EMI/RFI enclosures, router bases, LED driver housings, junction boxes.
- Why A380: Thin-wall filling for heat-sink fins; shielding when coated; excellent net-shape threads/bosses.
- Specs & notes: Mask ground pads before coating; maintain 1.2–1.8 mm fins with generous draft for ejection.
Pumps, valves & fluid handling
- Typical parts: Impeller covers, volute housings, meter bodies, filter heads.
- Why A380: Strength and pressure-tightness with high feature density; corrosion managed through coatings.
- Specs & notes: Vacuum casting recommended; leak test at 0.5–1.0 MPa air/helium depending on duty.
Power tools & garden equipment
- Typical parts: Gear cases, motor housings, clutch covers, handle frames.
- Why A380: Weight reduction vs. steel stampings; high stiffness; good drop resistance when ribbed.
- Specs & notes: Shot peen or bead blast for paint key; radius internal corners ≥ 0.5 mm to avoid cold shuts.
Rail, aerospace interiors & structures
- Typical parts: Seat frames, actuator housings, duct clamps, trim mounts.
- Why A380: Net-shape, fast cycle; adequate strength/stiffness for non-primary structure.
- Specs & notes: Anodize only when cosmetic expectations are modest; prefer conversion + paint.
Application selection table
| Industry | Part examples | Typical wall | Finishing workflow | Notes |
|---|---|---|---|---|
| Automotive/EV | Motor, inverter, transmission housings | 1.5–3.0 mm | Bead blast → phosphate/zirconium → powder | Leak test 10–30 mbar/min |
| Industrial | Pump covers, manifolds, gearbox lids | 2.0–3.5 mm | Bead blast 120–180 grit → paint | Add 0.3–0.5 mm machining stock |
| HVAC/Appliance | Compressor shells, blower frames | 2.0–3.0 mm | Pre-bake → e-coat/powder | Control outgassing |
| Electronics/Lighting | EMI boxes, LED drivers, heatsinks | 1.2–2.0 mm | Mask pads → conversion → paint | Draft fins ≥ 1°, spacing ≥ 2 mm |
| Fluid Handling | Volutes, meter bodies, filter heads | 2.5–4.0 mm | Vacuum cast → paint | Helium or air leak test |
| Tools/Outdoor | Gear cases, motor housings | 2.0–3.0 mm | Bead/shot → paint | Ribs for drop strength |
Case note
- Part: EV inverter housing, 2.0–3.0 mm walls, 4 sliders, cavity 1.9 kg.
- Process: 1250-ton cold-chamber, melt 680 °C, die 200 °C, gate velocity 55 m/s, vacuum ≤ 25 mbar.
- Result: Cosmetic class A after bead + powder; leak ≤ 10 mbar/min; FPY to machining > 93 % after vent re-balance.
FAQs:
Is A380 the same as ADC12 or EN AC-46000?
Not identical, but close enough for many projects with print approval. A380 (Al-Si-Cu ~Si 7.5–9.5%, Cu 2.0–3.5%) typically maps to EN AC-46000/46500 (AlSi9Cu3) and, in Asia, ADC12 (closer to A383). Always compare chemistry & critical properties; for pressure-tight work, run validation coupons.
What minimum wall thickness is realistic with A380 on 800–2000-ton machines?
With good gating and a warm die, 1.5–2.0 mm walls and 0.8–1.2 mm rib tips are routine; highly optimized tools can push walls toward 1.2–1.4 mm on short flow lengths. Use generous draft (≥1°) and continuous metal flow to avoid cold shuts.
Can A380 make pressure-tight housings without impregnation?
Yes—use vacuum die casting (≤25 mbar cavity vacuum), balanced vents and short fill times (<0.10 s for 2–3 mm walls). Typical leak-test targets are ≤10–30 mbar/min (air) for inverter/gear housings; many programs meet helium ≤1×10⁻³ mbar·L/s with process control.
A380 vs A360: which is better for corrosion and leak-tight parts?
A360 generally wins for corrosion and pressure tightness; A380 wins for castability/cost. If you need both thin-wall fill and higher corrosion margin, validate A360 or add a robust conversion-coat + powder system on A380.
Does A380 anodize well?
Only for muted/gray cosmetic finishes—the high Si content darkens conventional anodize. For bright or color-critical surfaces, prefer conversion coat (Zr/Cr-free) + powder or e-coat.
What is the as-cast strength of A380?
Typical room-temperature ranges: UTS ~320–330 MPa, YS ~150–165 MPa, elongation ~3–4 % (thickness and cooling matter). Brinell hardness is about ~80 HB.
Can A380 be heat treated (T5/T6) to raise strength?
Classic T6 is not recommended for die castings due to blister/porosity risk. Aged stabilizing cycles can tweak hardness slightly, but most A380 parts run as-cast with coating.
What thermal figures should I design around for heat spreaders?
Use thermal conductivity ~90–105 W/m·K and CTE ~21–23 µm/m·K. For better corrosion in hot/wet duty, pair with e-coat/powder over a conversion coat.
What machining allowance should I specify for gasket faces and bores?
Common practice is 0.3–0.5 mm on sealing faces and bearing bores, then skim/final ream after stabilization. Pre-bake before powder to avoid outgassing on thick bosses.
What are realistic cost levers for A380 parts?
Biggest levers are cavity count & cycle time, scrap rate (vacuum + venting), and secondary ops (machining & coating). Moving from single to multi-cavity on a correctly sized press typically drops piece price more than chemistry substitutions.
Work with YongZhu die-casting team that owns the process
We run 800–2000-ton cold-chamber machines for A380, A360 and ADC12 programs. If you need help choosing alloy, wall thickness, vacuum level or finishing stack, send your print—we’ll return DFM + cost-neutral suggestions and sample timelines.
