Post on 21-Jul-2016
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INTERZINC
• Market Development Organization
• Promote zinc alloy castings
• Zinc is the fourth most commonly
used metal in the world
• Zinc has unique properties that are
ideal for numerous applications
3
Members
Zinc Producer
– Teck, Xstrata Zinc
Alloyer
– Eastern Alloys, Midland Industries,
Ritchey Metals
Associate
– IZA, Dynacast, Lakeside Casting
Solutions
4
Program
Overview all aspects of zinc alloy diecasting
• Alloys & Specifications,
• Casting Processes,
• Physical and Mechanical properties,
• Surface Finishing,
• Design
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Power Seat Adjuster Gear Box – Zamak 3
8 Gear Shift Lever Bracket – ZA8
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Card Guide Ejector - Zamak 3
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Physical Properties
• Melting Temperature
• Density
• Thermal Conductivity
• Electrical Conductivity
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12
Front Plate
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Switch, Pogo Block, and Base – Zamak 3
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0
1
2
3
4
5
6
7
8
9
10 Z
n #
3
Zn
#5
ZA
-8
ZA
-12
ZA
-27
A3
80 A
l
AZ
-91D
Mg
C9
32
00
Cu
Du
cti
le Iro
n
AB
S
PP
Ny
lon
66/6
Ny
lon
66/6
3
0%
Gla
ss
(g/c
m3)
Density (g/cm3)
Zinc Alloys Other Metals Plastics
15
16
0
20
40
60
80
100
120
140 Z
n #
3
Zn
#5
ZA
-8
ZA
-12
ZA
-27
A3
80 A
l
AZ
-91D
Mg
C9
32
00
Cu
Du
cti
le Iro
n
AB
S
PP
Ny
lon
66/6
Ny
lon
66/6
3
0%
Gla
ss
(W/m
°K @
20
°C
)
Thermal Conductivity (W/m°K @ 20 °C)
Zinc Alloys Other Metals Plastics
17
18
0
5
10
15
20
25
30
35 Z
n #
3
Zn
#5
ZA
-8
ZA
-12
ZA
-27
A3
80 A
l
AZ
-91D
Mg
C9
32
00
Cu
Du
cti
le Iro
n
AB
S
PP
Ny
lon
66/6
Ny
lon
66/6
3
0%
Gla
ss
(% I
AC
S @
20
°C
)
Electrical Conductivity (%IACS @ 20 °C)
Zinc Alloys Other Metals Plastics
19
20
Mechanical Properties
• Tensile Strength
• Yield Strength
• Young’s Modulus
• Impact Strength
• Elongation
• Hardness
• Fatigue Strength
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0
50
100
150
200
250
300
350
400
450
500 Z
n #
3
Zn
#5
ZA
-8
ZA
-12
ZA
-27
A3
80 A
l
AZ
-91D
Mg
C9
32
00
Cu
Du
cti
le Iro
n
AB
S
PP
Ny
lon
66/6
Ny
lon
66/6
3
0%
Gla
ss
(MP
a)
Ultimate Tensile Strength (MPa)
Zinc Alloys Other Metals Plastics
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0
50
100
150
200
250
300
350
400 Z
n #
3
Zn
#5
ZA
-8
ZA
-12
ZA
-27
A3
80 A
l
AZ
-91D
Mg
C9
32
00
Cu
Du
cti
le Iro
n
AB
S
PP
Ny
lon
66/6
Ny
lon
66/6
3
0%
Gla
ss
(MP
a)
Yield Strength (MPa)
Zinc Alloys Other Metals Plastics Zinc Alloys Other Metals Plastics
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24
25
26
0
10
20
30
40
50
60
70 Z
n #
3
Zn
#5
ZA
-8
ZA
-12
ZA
-27
A3
80 A
l
AZ
-91D
Mg
C9
32
00
Cu
Du
cti
le Iro
n
AB
S
PP
Ny
lon
66/6
Ny
lon
66/6
3
0%
Gla
ss
Jo
ule
s
Impact Strength (J)
Zinc Alloys Other Metals Plastics
27
Add xelerator
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Bearing and Wear
Resistance
• Lower wear rate than C93200 Bronze
• Lower friction co-efficient than
C93200 Bronze
• 25% - 45% lighter than copper alloys
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Bearings – ZA12
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Surface Finishing
• Corrosion of Zinc
• Surface Finishing
Options
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Zinc Corrosion Rate
• The frequency and duration of
moisture contact
• The amount of acid or alkali in
atmosphere
• Retention or removal of corrosive
deposits
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Acid Alkaline
pH 7 is neutral
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Zinc castings
can accept a
wide range of
surface finishes
• Metal Plate
• Paint
• Conversion
coatings
Coatings
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Coating Systems Aesthetic: decorative finishes
• Gold, Silver, Brass, Chrome, Nickel
• stainless steel, leather, wood grain
Protection: corrosion resistance
• For aggressive environments, such as marine and industrial sites
Performance: engineering properties
• Increased wear resistance and electric conductivities
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www.hansa.com
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Example: Spray Painted car door side
panel and Dip Coated door handle
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Die Casting Design • Transformation of geometry to get:
– Improved product performance
– Die castable design
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Draft
• Tapered walls for
removal from die
• Internal walls more
critical
• Zinc provides
lowest draft angle
• Zero draft possible
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Ribbing
Ribs reduce mass,
improve metal flow
and add strength.
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Fillets
• Remove sharp corners and edges
• Fillet even the smallest features
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Consolidation
• Reduce number of parts
• Reduce types of materials
• Reduce Manufacturing
steps
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PRNDL Tube
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PRNDL Tube – ZA8
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Connecting Rod / Piston ZA12
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Antenna Amp Housing • Electrical Conductivity: RF
shielding
• Excellent Fluidity: Thin
walls / fins
• Low Heat Content: Long
Die Life
• Corrosion Resistance:
Outside environment
• High Strength: For rough
handling / protection
• Accuracy: Eliminated
gaskets retaining weather
tightness – and no RF
Leakage
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Casting Zinc
• Excellent casting versatility
• Select most economical process
based on:
– Production volumes
– Casting requirements
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Casting Processes
• Pressure Die
• Permanent mould
• Graphite Permanent mould
• Sand
• Shell
• Plaster
• Other
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Process Selection
PRESSURE DIE CASTING
PERMANENT MOLD CASTING
SAND CASTING
PIECE PRICE
INCREASING
INCREASING
TOOLING COST
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Pressure Die Casting
• Net-shape process
• Hardened Steel Tooling
• Medium to High Volume
• Production rates from 200 to
1000 shots per hour
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Stabilizer Link Rod
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Computer Card support
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Plaster board insert
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Miniature
Die
Casting
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Alloy Composition
ELEMENT ZAMAK ALLOYS ZA ALLOYS
No.2 No.3 No.5 No.7 ZA-8 ZA-12 ZA-27
Aluminum 4 4 4 4 8 11 27
Magnesium 0.04 0.04 0.05 0.015 0.02 0.02 0.015
Copper 3 - 1 - 1 0.85 2.25
Nickel - - - 0.013 - - -
Hot Chamber
Pressure Die Casting
Hot
Cold Chamber Note: Values
in weight % Chamber
Gravity Casting
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Specifications
Specifying Specification
Country Organization Ingots Castings
International
U.S.A.
ISO
ASTM
301
B 240
15201
B 86
Canada CSA HZ.3 HZ.11
Japan JIS H 2201 H 5301
U.K. CEN EN 1776
Australia SAS AS 1881
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Zamak 3 Alloy
Element
Composition (wt%)
Alloy Ingot Die Casting
(ASTM B240) (ASTM B86)
Aluminum 3.9-4.3 3.5-4.3
Magnesium 0.025-0.05 0.020-0.05
Copper (max) 0.10 0.25
Iron (max) 0.075 0.100
Lead (max) 0.004 0.005
Cadmium (max) 0.003 0.004
Tin (max) 0.002 0.003
Zinc (99.99%) Balance Balance
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On-Line Resources
• interzinc.com
• zinc-diecasting.info
• diecastingdesign.org
• zinc.org