product industries, such as communica- tions, electronics and home appliances. Zinc alloys most often are diecast—a
W
process in which molten metal is injected into metal molds at high pressure— because it provides the material with optimum surface finish and an ability to produce complex parts at a reduced cost. Te alloys also can be sand cast to produce a prototype component; how- ever, alloy control is critical in achieving similar properties to those achieved via diecasting. Zinc components range in size from less than an ounce (termed miniature zinc casting) up to 6 lbs.
Properties Zinc has the ability to produce:
• Complex Shapes—Te complex shapes produced with diecast zinc alloys are the closest any metallic alloy system can come to equaling thermoplastics. Te ability exceeds that of sheet stamp- ing, extrusion or machining. In addi- tion, extra shape complexity comes at a small cost compared to other processes;
• Fine Surface Finish—Te surface finish on a diecast zinc component is unsurpassed by any other diecast metal. In addition, electroplated and painted finishes can equal or exceed the aesthetic qualities of similar finishes on molded thermoplastics
Zinc Alloys
hile traditionally focused in automotive, hardware and plumbing markets, diecast zinc alloys are used in some consumer
Zinc die castings can be made to look like solid gold, weathered brass or stainless steel when the right surface finish is applied.
while providing an engineered struc- ture only possible with metal;
• High Mechanical Properties at Low Cost—Zinc is not an inexpensive ma- terial, but the diecasting process uses a minimum amount of metal to produce components. In addition, the ability to
produce complex shapes allows for the consolidation of several components into a single zinc die casting, eliminat- ing product and assembly costs down the road. Zinc die castings also can be made to a 0.02-in. wall thickness, which allows for conversions from
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. 2014 CASTING SOURCE DIRECTORY
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. METAL CASTING DESIGN & PURCHASING 41
Young’s Modulus, (psi x 106
) (ksi)
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