Table 1. Comparison of Zinc Alloy Properties With Other Materials Material
Tensile Strength (ksi)
Die Cast Alloys Zinc Alloy 3
ZA-8 ZA-27
380 Aluminum AZ91 Magnesium
Sheet Steels Draw Quality
HSLA Powdered Iron
Plastics ABS
Polycarbonate
Nylon 6 (30% glass reinforced) PET (30% glass reinforced) PBT (30% glass reinforced)
This miniature zinc casket arm weighs less than 6 oz.
35 43 52 45 34
40 60 —
8 9
22 21 18
Yield Strength (ksi)
—
32 46 23 23
25-35 60 70
— — — — —
6.3
12.4 11.3
10.3 10.3
29.5 29.5
17.5-19.5
1.0 1.0 1.5
2.0 2.5
Source: Engineering Properties of Zinc Alloys, International Lead Zinc Research Organization Inc.
300F). It is nearly seven times as creep resistant as the ZA-8 alloy.
Design Considerations Creative design of a diecast zinc
component must begin with a clear statement that precisely defines the product functions to be performed. Af- ter product function has been defined, a configuration compatible with the diecasting process and the selected alloy must be developed. Alloy selection is based primarily on the required me- chanical, physical and chemical proper- ties of the component. For a product configuration optimized for diecasting, three factors must be considered: • Te ability to fill completely with metal.
• The ability to solidify quickly and without defects.
• The ability to eject from the die tooling. These factors can best be
achieved by applying six principles when designing diecast zinc compo- nent walls and sections and estab- lishing tolerances. 1. There are no hard and fast rules governing maximum and mini- mum limits for wall thicknesses. They should be as consistent as possible throughout the compo- nent, and where variations are required, transitions should be provided to avoid abrupt changes. Diecasters who use high-tech- nology equipment and techniques routinely produce castings with maximum and minimum wall thicknesses and with variations
42 METAL CASTING DESIGN & PURCHASING 2015 CASTING SOURCE DIRECTORY
Young’s Modulus, (psi x 106
) (ksi)
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