Web in Ar Zinc Innovations
63
1
Transcript of Web in Ar Zinc Innovations
1
2
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
5
6
7
Power Seat Adjuster Gear Box – Zamak 3
8 Gear Shift Lever Bracket – ZA8
9
Card Guide Ejector - Zamak 3
10
Physical Properties
• Melting Temperature
• Density
• Thermal Conductivity
• Electrical Conductivity
11
12
Front Plate
13
Switch, Pogo Block, and Base – Zamak 3
14
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
21
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
22
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
23
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
28
Bearing and Wear
Resistance
• Lower wear rate than C93200 Bronze
• Lower friction co-efficient than
C93200 Bronze
• 25% - 45% lighter than copper alloys
29
30
31
Bearings – ZA12
32
Surface Finishing
• Corrosion of Zinc
• Surface Finishing
Options
33
Zinc Corrosion Rate
• The frequency and duration of
moisture contact
• The amount of acid or alkali in
atmosphere
• Retention or removal of corrosive
deposits
34
Acid Alkaline
pH 7 is neutral
35
Zinc castings
can accept a
wide range of
surface finishes
• Metal Plate
• Paint
• Conversion
coatings
Coatings
36
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
37
www.hansa.com
38
Example: Spray Painted car door side
panel and Dip Coated door handle
39
40
Die Casting Design • Transformation of geometry to get:
– Improved product performance
– Die castable design
41
Draft
• Tapered walls for
removal from die
• Internal walls more
critical
• Zinc provides
lowest draft angle
• Zero draft possible
42
43
Ribbing
Ribs reduce mass,
improve metal flow
and add strength.
44
Fillets
• Remove sharp corners and edges
• Fillet even the smallest features
45
Consolidation
• Reduce number of parts
• Reduce types of materials
• Reduce Manufacturing
steps
46
PRNDL Tube
47
PRNDL Tube – ZA8
48
Connecting Rod / Piston ZA12
49
50
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
51
Casting Zinc
• Excellent casting versatility
• Select most economical process
based on:
– Production volumes
– Casting requirements
52
Casting Processes
• Pressure Die
• Permanent mould
• Graphite Permanent mould
• Sand
• Shell
• Plaster
• Other
53
Process Selection
PRESSURE DIE CASTING
PERMANENT MOLD CASTING
SAND CASTING
PIECE PRICE
INCREASING
INCREASING
TOOLING COST
54
Pressure Die Casting
• Net-shape process
• Hardened Steel Tooling
• Medium to High Volume
• Production rates from 200 to
1000 shots per hour
55
56
Stabilizer Link Rod
57
Computer Card support
58
Plaster board insert
59
Miniature
Die
Casting
60
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
61
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
62
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
63
On-Line Resources
• interzinc.com
• zinc-diecasting.info
• diecastingdesign.org
• zinc.org
