Shenzhen Alu Rapid Prototype Precision Co., Ltd.

In general, die-cast metal is not very malleable. Most die-cast parts are made from alloys designed for "castability" (the ability to flow into a mold) rather than "formability" (the ability to be bent or shaped afterward).While most die-cast metals are considered brittle, their actual behavior depends heavily on the specific alloy used.

1. Zinc Alloys (Most Malleable)

Zinc is the "king" of malleability in the die-casting world. If you have a die-cast part that needs to be slightly bent, crimped, or staked during assembly, it is almost certainly a zinc alloy (like Zamak).

Behavior: It has high impact strength and some ductility. You can often perform minor cold-forming (bending it slightly) without it snapping.

Applications: Zippers, toys, and complex automotive brackets.

2. Aluminum Alloys (Brittle)

Aluminum die-castings are generally quite brittle. They are favored for their light weight and strength-to-weight ratio, but they do not handle deformation well.

Behavior: If you try to bend a standard aluminum die-cast part (like an engine component or a laptop frame), it will usually snap or crack rather than deform.

The "Skin" Effect: Die-cast aluminum has a very hard, dense outer "skin" and a more porous core. Once you stress the part enough to crack that skin, the whole piece fails instantly.

3. Magnesium Alloys (Very Brittle)

Magnesium is the least malleable of the common die-casting metals.

Behavior: It is extremely rigid and has a hexagonal crystal structure that makes it very prone to fracturing if bent. It is chosen for parts that must stay exactly in their cast shape under stress.

Comparison of Properties