Because of their many advantageous qualities, die-cast alloys are the manufacturer’s first choice. Because they are so affordable, alloys based on zinc are among the most often used. Manufacturers offer a variety of zinc die casting alloys in their catalogs to meet consumer demand.
An overview of the varieties, properties, and uses of zinc alloys is provided in this article.
Features of Zinc Die Casting Alloy
Based on the chemical composition and other pertinent variables, the displaying property differs from alloy to alloy. On the other hand, zinc-based alloys share the following traits:
Die Casting Zinc Alloy (Figure 1)
- greater mechanical strength
- balanced physical attributes
- outstanding heat conductivity
- high level of corrosion resistance
- Simple connecting using a form that is cold
- Excellent dimensional precision
- Good qualities for bearing wear
The output is also significantly influenced by the zinc die casting technique. There are many techniques (hot, cold, or shot chamber) to suit different requirements.
Zinc Die Casting Alloys: Advantages
High Precision for Thin Walls: Because zinc alloys are sufficiently strong and resilient, design optimization to minimize wall thickness is feasible.
Putting in Complex Geometry: The bearing-wearing capacity of alloys serves as bushings for moving frames, making complex designs simple to achieve.
Quick Tool Production: It is possible to accelerate the process and raise the cycle rate by using a low melting point in opposition to high-pressure injection.
Various Finishing Options: Paint, coating, or plating appropriate for cast parts and machinery is made possible by excellent surface adherence.
Minimal Mechanical Failure: Precision-dimensional resilient casting combines excellent impact resistance with stiffness.
Completely friendly to the environment All of the waste materials and leftover components from zinc alloys can be recycled through remelting and recasting.
Common Alloys for Zinc Die Casting
Zinc-based alloys fall into one of two unique families. The traditional class calls for the alloy to be supplied in batches rather than as a single unit. They also go by the well-known “Zamak” name, which is associated with the alloy series number.
The following is a summary of conventional zinc casting alloys:
- ZA Series: This is a high-zinc content casting alloy that also includes small amounts of aluminum and copper. Common types include ZA-8, ZA-12, and ZA-27, where the numbers represent the percentage of aluminum content. ZA-8 can be used in both hot-chamber and cold-chamber casting, whereas ZA-12 and ZA-27 are typically used in cold-chamber casting.
- Zamak Series: This is the most common series of die casting zinc alloys, including Zamak 2, Zamak 3, Zamak 5, and Zamak 7. These alloys are primarily composed of zinc, aluminum, magnesium, and copper, with Zamak 3 being the most widely used due to its good mechanical properties and castability.
- ZA-8, ZA-12, ZA-27: These alloys offer higher strength and hardness than the Zamak series, especially ZA-27, which has the highest strength and hardness but poorer castability.
The majority of modern zinc alloys with higher aluminum concentrations are referred to as ZA (Zinc-Aluminum) alloys. However, since multiple companies are engaged, this isn’t always the case. Only complicated requirements with limited scale are met by these sophisticated alloys.
Some noteworthy zinc alloys with a high aluminum percentage are:
ZA-12, ZA-27, and ZA-8 (ZP8)
Superloy EZAC GDSL AcuZinc5
While alloys rich in aluminum fulfill specific needs, conventional alloys are mainly used in general manufacturing.
Zn Casting Alloys’ Industrial Uses
Zn alloys have a high strength that even certain aluminum alloys can’t equal. Despite the material’s drawbacks, this is the reason why many industries favor zinc. Zinc die casting alloys are widely used in the following applications:
Zinc alloy die casting components manufactured in various parts
Vehicle Components: They produce gears, pulleys, enclosures, door locks, sunroofs, rearview mirrors, stress-absorbing components, and wipers.
Medical Instruments: Zinc’s dimensional stability, high modulus, and self-lubricating quality are useful for sensitive medical equipment.
Electronics: Zamak 3’s dimensional stability is ideal for wall clocks, toggle switches, energy regulators, and resistors with ceramic casings.
Home appliances: Showpieces, door locks, frame handles, keychains, furniture joints, belts and holders, and other hardware all benefit from strength and finishing.
Mechanical Support: Casting alloys made of aluminum are not as capable of providing bracing or support as alloys with superior creep resistance and outstanding hardness.
Zinc alloys are not ideal for small-scale production, are heavier than their counterparts, and are far more prone to faults. Even though these materials have better qualities, their use is frequently limited. Aluminum, on the other hand, excels due to its global production scale, reduced defect rate, and light weight.
For 28years, Honjenny has been at the forefront of the aluminum die casting production industry. With your upcoming metal alloy projects, its highly regarded expert panel is prepared to assist you. Reach out to us with your ideas and plans for using our experience.
