Die-cast alloys are the ultimate choice of manufacturers due to their many beneficial properties. Zinc-based alloys are one of the most popular options due to their cost-effectiveness. Different Zinc die casting alloys are available in manufacturer catalogs to deal with customer demand.
The article takes a brief look into Zn alloy characteristics, advantages, and applications with their types.
Zinc Die Casting Alloy Characteristics
The exhibiting feature varies from alloy to alloy based on the chemical composition and relevant factors. However, the common characteristics of zinc-based alloys are –
- Superior mechanical strength
- Balanced physical properties
- Excellent thermal conductivity
- High resistance to corrosion
- Easy joining through a cold form
- Superb dimensional accuracy
- Good bearing-wear properties
The Zinc die casting process also exerts great influence in determining the outcome. Different methods (hot, cold, or shot chamber) are available to meet specific needs.
Advantages of Zinc Die Casting Alloys
- High Precision for Thin Walls– Design optimization to reduce the wall thickness is possible as Zn alloys are sufficiently robust/strong.
- Casting Complex Geometry– Alloys’ bearing-wearing capability acts as bushings for moving frames to obtain complex designs easily.
- Superfast Tool Production– A low melting point against high-pressure injection can speed up the process to increase the cycle rate.
- Different Finishing Options– Excellent surface adhesion enables painting, coating, or plating suitable for cast parts and machinery.
- Few Mechanical Failure– Resilient casting with dimensional precision integrates superior resistance to impact and rigidity.
- Fully Environment-Friendly– Remelting and recasting can recycle all the byproducts and discarded parts originating from Zn alloys.
Common Zinc Die Casting Alloys
There are two distinctive families to categorize zinc-based alloys. The conventional class features alloy in its name to come in a series instead of a singular entity. However, they also go by the popular ‘Zamak’ term featured with the alloy series’ number.
Conventional zinc casting alloys can be outlined as –
- Alloy 2 Series: ZP2, ZL2, Zamak 2, Kirksite, ZnAl4Cu3
- Alloy 3 Series: ZP3, ZL3, Zamak 3, ZDC2, ZnAl4
- Alloy 5 Series: ZP5, ZL5, Zamak 5, ZDC1, ZnAl4Cu1
- Alloy 7 Series: ZL7, Zamak 7
- High Fluidity Alloy (latest addition to Zamak family)
Modern zinc alloys with more aluminum contents are mostly abbreviated as ZA (Zinc-Aluminum). But it’s not always the case as different companies are involved. These advanced alloys are exclusively used to meet limited-scale complex requirements.
Noteworthy high aluminum content zinc alloys are –
- ZA-8 (ZP8)
- ZA-12
- ZA-27 (ZP27)
- EZAC
- GDSL (Superloy)
- ACuZinc5
Conventional alloys primarily serve general manufacturing purposes, whereas aluminum-rich alloys meet special requirements.
Industrial Uses of Zn Casting Alloys
Even some aluminum alloys can’t match the high strength of Zn alloys. That’s why many industries prefer Zn, despite the material’s downsides. Some of the renowned uses of Zinc die casting alloys include –
- Automobile Parts– They make gears, pulleys, enclosures, door locks, sunroofs, rearview mirrors, stress-bearing parts, and windshield wipers.
- Medical Instruments– Zinc’s self-lubricating property, high modulus, and dimensional stability effectively help with sensitive medical devices.
- Electronics– The dimensional stability of Zamak 3 perfectly serves energy regulators, wall clocks, toggle switches, and ceramic-encased resistors.
- Home Appliances– Strength and finishing are handy in furniture joints, belts/holders, keychains, door locks, frame handles, and showpieces.
- Mechanical Support– Superb creep resistance with excellent hardness can provide bracing or support better than aluminum casting alloys.
Zinc alloys are considerably prone to defects, heavier than their counterparts, and unsuitable for small-scale production. It often limits the applicability of these materials while having superior properties. However, aluminum stands on top with fewer defects, lightness, and universal-scale productions.
Sunrise Metal has been leading the aluminum die casting manufacturing market for over 10 years. Its acclaimed expert panel is ready to help you with the next metal alloy projects. Contact us to share your plan/thoughts on utilizing our experience.