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1)
Relative Characteristics of Die Casting Alloys
Aluminu m
Brass
Magnesiu m
Zinc
Dimension al stability
Good
Excelle nt
Excellent
Good
Corrosion resistance
Good
Excelle nt
Fair
Fair
Casting ease
Good
Fair
Good
Excelle nt
Part complexity
Good
Fair
Good
Excelle nt
Dimension al accuracy
Good
Fair
Excellent
Excelle nt
Die cost
Medium
High
Medium
Low
Machining cost
Low
Medium Low
Low
Finishing cost
Medium
Low
Low
High
2) The unique properties of zinc
include:
High-Quality Casting Capabilities: Zinc can achieve tighter tolerances than molded plastics or cast aluminum. Zinc offers a thin wall castability and the ability to cast to print with little to no draft.
Superior Mechanical Properties: Zinc features excellent bearing and tensile strength, as well as rigidity.
Exceptional Physical Properties: Zinc conducts electricity while dissipating heat.
Multiple Finishing Options: Zinc is suitable for a variety of finishing options for cosmetic and anti-corrosion purposes, including: electroplating, overmolding, powder coating, chrome plating, PVD (physical vapor deposition) and CVD (chemical vapor deposition).
Environmentally Sustainable: All zinc materials are non-toxic and can be recycled.
3) Lead and Tin Alloys
Lead and tin alloys enjoy only minor use in die casting since their strengths are low. Lead die castings find applications where high density (wheel weights) or corrosion resistance (plumbing goods) is needed. Tin may be found in small parts where extremely close dimensional tolerances are needed, or where contact with food or certain chemicals may be encountered.
4) Alloys Description Alloy
Zamak 3
Zamak 5
Zamak 7
Zamak 2
Description No. 3 alloy is usually the first choice when considering zinc die casting. Its excellent balance of desirable physical and mechanical properties, superb castability and long-term dimensional stability are the reasons why over 70% of all North American zinc die castings are in No. 3 alloy. It is, therefore, the most widely available alloy from die casting sources. ZAMAK No. 3 also offers excellent finishing characteristics for plating, painting and chromate treatments. It is the "standard" by which other zinc alloys are rated in terms of die casting. No. 5 alloy castings are marginally stronger and harder than No. 3. However, these improvements are tempered with a reduction in ductility which can affect formability during secondary bending, riveting, swaging or crimping operations. No. 5 contains an addition of 1% copper which accounts for these property changes. The alloy is widely die cast in Europe and does exhibit excellent castability characteristics, as well as, improved creep performance over No. 3. Because of No. 3's wide availability, material specifiers often strengthen components by design modifications instead of using No. 5. However, when an extra measure of tensile performance is needed, No. 5 alloy castings are recommended. The alloy is readily plated, finished and machined, comparable to No. 3 alloy. No. 7 alloy is a modification of #3 alloy in which lower magnesium content is specified in order to increase the fluidity. To avoid problems with inter-granular corrosion lower levels of impurities are called for and a small quantity of nickel is specified. Alloy #7 has slightly better ductility than #3 with other properties remaining at the same level. The alloy is therefore popular for those special cases where the die caster is making thin walled components requiring a good surface finish. However, research testing has shown that metal and die temperatures have a bigger effect than changing alloys. Close attention to control of the die casting process parameters is important so as to eliminate defects and achieve consistent quality. No. 2 is the only ZAMAK alloy which is used for gravity casting; mainly for metal forming dies or plastic injection tools. This alloy is sometimes referred to as Kirksite. For die casting, No. 2 offers the highest strength and hardness of the ZAMAK family. However, its high copper content (3%) results in property changes upon long term aging.
Alloy
ZA-8
ZA-12
Description These changes include slight dimensional growth (0.0014 in/in/after 20 yrs.), lower elongation and reduced impact performance (to levels similar to aluminum alloys) for die cast products. Although No. 2 alloy exhibits excellent castability, it has seen limited use by die casters in North America. It does, however, provide some interesting characteristics which may assist designers. Its creep performance is rated higher than the other ZAMAKs and No. 2 maintains higher strength and hardness levels after long term aging. Also, preliminary investigations suggest No. 2 alloy is a good bearing material, and may eliminate bushings and wear inserts in die cast designs. A good gravity casting alloy, ZA-8 is rapidly growing for pressure die casting. ZA-8 can be hot chamber die cast, with improved strength, hardness and creep properties over ZAMAK's, with the exception of a No. 2 alloy which is very similar in performance. ZA-8 is readily plated and finished using standard procedures for ZAMAK. When the performance of standard No. 3 or No. 5 is in question, ZA-8 is often the die casting choice because of high strength and creep properties and efficient hot chamber castability. ZA-12 is the most versatile zinc alloy in terms of combining high performance properties and ease of fabrication using either gravity or pressure die casting. ZA-12 is the best gravity casting alloy for sand, permanent mold and the new graphite mold casting process. It is also a good pressure die casting alloy (cold chamber) which provides a sounder structure than ZA-27, as well as higher die cast elongation and impact properties. For these reasons, die cast ZA-12 often competes with ZA-27 for strength application. An excellent bearing alloy, ZA-12 is also platable, although plating adhesion is reduced compared to the ZAMAK alloys.
Chemical Specification (per ASTM) (% by Weight) for ZAMAK Alloys
Zamak 3
Zamak 5
Zamak 7
Zamak 2
Ingot
Ingot
Ingot
Ingot
Casting
Casting
Casting
Al
3.9-4.3 3.7-4.3
3.9-4.3 3.7-4.3
Mg
.03-.06 .02-.06
.03-.06
.02.06
.01-.02 .005-.02 .025-.0
.02-.06 0 0 5
Cu
.10 max .1 max
.7-1.1
.7-1.2
.10 max
.1 max
2.7-3.3 2.6-3.3
Fe (max)
.035
.05
.035
.05
.035
.035
.035
.05
Pb (max)
.0040
.005
.0040
.005
.0030
.003
.0040
.005
Cd (max)
.0030
.004
.0030
.004
.0020
.002
.0030
.004
Sn (max)
.0015
.002
.0015
.002
.0010
.001
.0015
.002
Ni (other)x10
.005-.0 .005-.02 20 0
Zn
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Color Code None ASTM B908
3.9-4.3 3.7-4.3
Casting
Black
Bal.
3.9-4.3 3.7-4.3
Bal.
Brown
Green
Chemical Specification (per ASTM) (% by Weight) for ZA Alloys
ZA-8
ZA-12
ZA-27
Ingot
Casting
Ingot
Casting
Ingot
Casting
Al
8.2-8.8
8.0-8.8
10.8-11.5 10.5-11.5
25.5-28.0 25.0-28.0
Mg
.02-.03
.01-.03
.02-.03
.01-.03
.012-.020 .01-.02
Cu
0.9-1.3
.8-1.3
0.5-1.2
0.5-1.2
2.0-2.5
2.0-2.5
Fe (max)
.035
.075
.05
.075
.07
.075
Pb (max)
.005
.006
.005
.006
.005
.006
Cd (max)
.005
.006
.005
.006
.005
.006
Sn (max)
.002
.003
.002
.003
.002
.003
Ni (other)x10
Chemical Specification (per ASTM) (% by Weight) for ZA Alloys
ZA-8 Zn
ZA-12
ZA-27
Ingot
Casting
Ingot
Casting
Ingot
Casting
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Color Code Blue ASTM B908
Orange
Purple
5) zinc alloys
----High density
High ductility
Good impact strength
Excellent surface smoothness allowing for painting or plating
Requires such coating due to susceptibility to corrosion
Easiest to cast
Can form very thin walls
Long die life due to low melting point
Use of a hot chamber machine
--------------------------------------------------------------------------------------------------------------------Zinc-based alloys (Table 2) are the easiest to die cast. Ductility is high and impact strength is excellent, making these alloys suitable for a wide range of products. Zinc alloys can be cast with thin walls and excellent surface smoothness making preparation for plating and painting relatively easy. It is essential that only high purity (99.99 + 0/0) zinc metal be used in the formulation of alloys. Low limits on lead, tin and cadmium ensure the long-term integrity of the alloys strength and dimensional stability
6) za family -----------------------------------------------------------------------------------------------------------------ZA-8, or zinc aluminum alloy, contains significantly more aluminum than the Zamak group of alloys. ZA-8 contains approximately 8.4% aluminum and is the only ZA alloy that can be hotchamber die cast, an important consideration when selecting a material for a component.
ZA-8 has excellent finishing and plating characteristics and was originally developed as a permanent mold alloy
It is ideal for decorative applications
Although it does not have as good casting characteristics as the other zinc alloys, it offers significantly improved strength, hardness, and creep properties
In terms of mechanical performance, ZA 8 has the highest creep strength of any zinc alloy and the highest strength of any hot-chamber die cast zinc alloy
Mechanical Properties
Imperial US/UK| Metric
Yield Tensile Impact Shear Material Alloy Strength Hardness Elongation Process Strength Strength Strength (0.2%) Brinell MPa MPa J MPa % in 50mm (HB) HotChamber Zinc ZA 8 374 290 42 275 103 6 Die Casting
Physical Properties Imperial US/UK | Metric Melting Point Material Alloy Density (Average +/- 50) 3 g/cm C Zinc ZA 8 6.3 390
Thermal Conductivity
Coefficient of Electrical Thermal Conductivity Expansion
W/m K 114.7
m/mK 23.3
%IACS 27.7
Process
HotChamber
Melting Point Material Alloy Density (Average +/- 50) 3 g/cm C
Thermal Conductivity
Coefficient of Electrical Thermal Conductivity Expansion
W/m K
m/mK
Process
%IACS Die Casting
7) RELATIVE ALLOY WEIGHTS TO MAGNESIUM
Aluminum 1.6 Zinc
3.7
ZA Alloys
2.73.4
Magnesium 1.0
8)
Brass
4.7
Tin
4.0
Lead
6.3
Bronze
4.9
Zinc Alloys
Zinc-based materials are relatively easy to die cast, and respond well to the die molding process. These materials are comprised of multiple metals in specific ratios. For example, a typical zinc-based die casting workpiece consists of 86 percent zinc, 4 to 7 percent copper, and 7 to 10 percent tin. Slightly higher proportions of tin make the workpiece more flexible, while increased copper levels improve rigidity. Zinc alloys have a melting point in the range of 700 to 800 degreees Fahrenheit. Zinc alloys are often used in place of cast iron or brass, but tend to have lower tensile strength than their sturdier counterparts. Unless it is specially reinforced during the alloying process, zinc-based material cannot exceed approximately 17,000 pounds per square inch of force. As a result, die cast zinc products are generally not used in applications involving high mechanical loads. Zinc castings can also be corroded by alkaline substances or salt-water, and are often plated to preserve their luster despite atmospheric conditions.
Tin Alloys Alloys composed with a significant amount of tin as a base metal are most often used in applications requiring corrosion resistance, such as those involving the food industry or internal and external bearings. While the proportion of metals in these alloys can vary widely, a typical tin alloy consists of 90 percent tin, 6 percent antimony, and 4 percent copper, which is added to strengthen the materials durability. Tin alloy die castings generally weigh under ten pounds and rarely exceed 1/32 of an inch in thickness. They are valued for their resistance to alkaline, acids, and water, but feature a comparatively low tensile strength rating of below 8,000 pounds per square inch. Bronze and Brass Alloys Most bronze and brass materials can be die cast as effectively as zinc-based alloys, although small holes can only be drilled into the workpiece after casting, rather than during the casting process. Bronze and brass are commonly used to create washers, camshaft components, and decorative products (due to their distinctive coloring and potential for surface finishes). A typical brass alloy consists of 60 percent copper, 40 percent zinc, and 2 percent aluminum, but there are many variations on this mixture. Die casting bronze and brass is capable of yielding products with a durable surface and highly accurate interior specifications. Some brasses have difficulty tolerating shrinkage from high temperature processes, but despite these challenges, most of these alloys can be used for products weighing up to fifteen pounds and with thicknesses at or under 1/32 of an inch. They are generally suitable for applications requiring tensile strength of less than 8000 pounds per square inch. Aluminum Alloys Die cast aluminum alloys are often found in automobile parts and gears, and have been used to create surgical instruments in the past. They are generally stronger and lighter than most zinc-based materials, but tend to be more expensive to create. Using aluminum alloys can reduce the need for finishing treatments, such as plating, and a common grade is composed of 92 percent aluminum mixed with 8 percent copper. Magnesium may be added to this alloy to improve its tensile strength from around 21,000 pounds per square inch to approximately 32,000 per square inch, while nickel
can be included to increase rigidity and provide a higher surface finish. The melting point for an aluminum alloy is around 1150 degrees Fahrenheit. Lead Alloys Like tin alloys, lead-based materials tend to be used for their corrosion resistance and in applications requiring no more than 8000 pounds of tensile strength per square inch. Common applications include fire-safety equipment, bearings, and various decorative metal goods. They are relatively inexpensive for producing castings under 15 pounds, but lead alloys cannot be used for products that will be in contact with food. A typical lead alloy might be 90 percent lead and 10 percent antimony, with tin being a common addition as well. The melting point is usually around 600 degrees Fahrenheit, and product thickness rarely exceeds 1/32 of an inch.
