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Zamak
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ZAMAK (or Zamac, formerly trademarked as MAZAK[1]) is an eclectic family of alloys with a base metal of zinc and alloying elements of aluminium, magnesium, and copper.
Zamak alloys are part of the zinc aluminium alloy family; they are distinguished from the other ZA alloys because of their constant 4% aluminium composition.[2]
The name zamak is an acronym of the German names for the metals of which the alloys are composed: Zink (zinc), Aluminium, Magnesium and Kupfer (copper).[2] The New Jersey Zinc Company developed zamak alloys in 1929.
The most common zamak alloy is zamak 3. Besides that, zamak 2, zamak 5 and zamak 7 are also commercially used.[2] These alloys are most commonly die cast.[2] Zamak alloys (particularly #3 and #5) are frequently used in the spin casting industry.
A large problem with early zinc die casting materials was zinc pest, owing to impurities in the alloys.[3] Zamak avoided this by the use of 99.99% pure zinc metal, produced by New Jersey Zinc's use of a refluxer as part of the refining process.
Zamak can be electroplated, wet painted, and chromate conversion coated well.[4]
Mazak
[edit]In the early 1930s, Morris Ashby in Britain had licensed the New Jersey zamak alloy. The 99.99%-purity refluxer zinc was not available in Britain and so they acquired the right to manufacture the alloy using a locally available electrolytically refined zinc of 99.95% purity. This was given the name Mazak, partly to distinguish it from zamak and partly from the initials of Morris Ashby. In 1933, National Smelting licensed the refluxer patent with the intent of using it to produce 99.99% zinc in their plant at Avonmouth.[5]
Standards
[edit]Zinc alloy chemical composition standards are defined per country by the standard listed below:
| Country | Zinc ingot | Zinc casting |
|---|---|---|
| Europe | EN1774 | EN12844 |
| US | ASTM B240 | ASTM B86 |
| Japan | JIS H2201 | JIS H5301 |
| Australia | AS 1881 - SAA H63 | AS 1881 - SAA H64 |
| China | GB 8738-88 | - |
| Canada | CSA HZ3 | CSA HZ11 |
| International | ISO 301 | - |
Zamak goes by many different names based on standard and/or country:
| Traditional name | Short composition name | Form | Common | ASTM† | Short European designation | JIS | China | UK BS 1004[7] | France NFA 55-010[7] | Germany DIN 1743-2[7] | UNS | Other |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Zamak 2[8][9] or Kirksite[10] |
ZnAl4Cu3[11] | Ingot | Alloy 2[8][9] | AC 43A[8][9] | ZL0430[11] | - | ZX04[12] | - | Z-A4U3[11] | Z430[11] | Z35540[9] | ZL2, ZA-2, ZN-002[13] |
| Cast | ZP0430 | - | Z35541[8] | ZP2, ZA-2, ZN-002[13] | ||||||||
| Zamak 3[8][9] | ZnAl4[11] | Ingot | Alloy 3[8][9] | AG 40A[8][9] | ZL0400[11] | Ingot type 2[14] | ZX01[12] | Alloy A[11] | Z-A4[11] | Z400[11] | Z35521[9] | ZL3, ZA-3, ZN-003[13] |
| Cast | ZP0400 | ZDC2[15] | - | Z33520[8] | ZP3, ZA-3, ZN-003[13] | |||||||
| Zamak 4[16] | Ingot | Used in Asia only | ZA-4, ZN-004[13] | |||||||||
| Zamak 5[8][9] | ZnAl4Cu1[11] | Ingot | Alloy 5[8][9] | AC 41A[8][9] | ZL0410[11] | Ingot type 1[14] | ZX03[12] | Alloy B[11] | Z-A4UI[11] | Z410[11] | Z35530[9] | ZL5, ZA-5, ZN-005[13] |
| Cast | ZP0410 | ZDC1[15] | - | Z35531[8] | ZP5, ZA-5, ZN-005[13] | |||||||
| Zamak 7[8][9] | ZnAl4Ni[12] | Ingot | Alloy 7[8][9] | AG 40B[8][9] | - | - | ZX02[12] | - | - | - | Z33522[9] | ZA-7, ZN-007[13] |
| Cast | - | Z33523[8] | ||||||||||
| †color of the cell is the color of the material designated by ASTM B908.[2] | ||||||||||||
The short European designation code breaks down as follows (using ZL0430 as the example):[11]
- Z is the material (Z = zinc)
- P is the use (P = pressure die casting (casting), L = ingot)
- 04 is the percent aluminum (04 = 4% aluminum)
- 3 is the percent copper (3 = 3% copper)
Zamak 2
[edit]Zamak 2 has the same composition as zamak 3 with the addition of 3% copper in order to increase strength by 20%, which also increases the price. Zamak 2 has the greatest strength out of all the zamak alloys. Over time it retains its strength and hardness better than the other alloys; however, it becomes more brittle, shrinks, and is less elastic.[17]
Zamak 2 is also known as Kirksite when gravity cast for use as a die.[2][18] It was originally designed for low volume sheet metal dies.[19][20] It later gained popularity for making short run injection molding dies.[19] It is also less commonly used for non-sparking tools and mandrels for metal spinning.
| Alloying elements | Impurities | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Standard | Limit | Al | Cu | Mg | Pb | Cd | Sn | Fe | Ni | Si | In | Tl |
| ASTM B240[21] (Ingot) | min | 3.9 | 2.6 | 0.025 | - | - | - | - | - | - | - | - |
| max | 4.3 | 2.9 | 0.05 | 0.004 | 0.003 | 0.002 | 0.075 | - | - | - | - | |
| ASTM B86[22] (Cast) | min | 3.5 | 2.6 | 0.025 | - | - | - | - | - | - | - | - |
| max | 4.3 | 2.9 | 0.05 | 0.005 | 0.004 | 0.003 | 0.1 | - | - | - | - | |
| EN1774[23] (Ingot) | min | 3.8 | 2.7 | 0.035 | - | - | - | - | - | - | - | - |
| max | 4.2 | 3.3 | 0.06 | 0.003 | 0.003 | 0.001 | 0.02 | 0.001 | 0.02 | - | - | |
| EN12844[24] (Cast) | min | 3.7 | 2.7 | 0.025 | - | - | - | - | - | - | - | - |
| max | 4.3 | 3.3 | 0.06 | 0.005 | 0.005 | 0.002 | 0.05 | 0.02 | 0.03 | - | - | |
| GB8738-88[12] | min | 3.9 | 2.6 | 0.03 | - | - | - | - | - | - | - | - |
| max | 4.3 | 3.1 | 0.06 | 0.004 | 0.003 | 0.0015 | 0.035 | - | - | - | - | |
| Property | Metric value | Imperial value |
|---|---|---|
| Mechanical properties | ||
| Ultimate tensile strength | 397 MPa (331 MPa aged) | 58,000 psi |
| Yield strength (0.2% offset) | 361 MPa | 52,000 psi |
| Impact strength | 38 J (7 J aged) | 28 ft-lbf (5 ft-lbf aged) |
| Elongation at Fmax | 3% (2% aged) | |
| Elongation at fracture | 6% | |
| Shear strength | 317 MPa | 46,000 psi |
| Compressive yield strength | 641 MPa | 93,000 psi |
| Fatigue strength (reverse bending 5x108 cycles) | 59 MPa | 8,600 psi |
| Hardness | 130 Brinell (98 Brinell aged) | |
| Modulus of elasticity | 96 GPa | 14,000,000 psi |
| Physical properties | ||
| Solidification range (melting range) | 379–390 °C | 714–734 °F |
| Density | 6.8 kg/dm3 | 0.25 lb/in3 |
| Coefficient of thermal expansion | 27.8 μm/m-°C | 15.4 μin/in-°F |
| Thermal conductivity | 105 W/m-K | 729 BTU-in/hr-ft2-°F |
| Electrical resistivity | 6.85 μΩ-cm at 20 °C | 2.70 μΩ-in at 68 °F |
| Latent heat (heat of fusion) | 110 J/g | 4.7x10−5 BTU/lb |
| Specific heat capacity | 419 J/kg-°C | 0.100 BTU/lb-°F |
| Coefficient of friction | 0.08 | |
KS
[edit]The KS alloy was developed for spin casting decorative parts. It has the same composition as zamak 2, except with more magnesium in order to produce finer grains and reduce the orange peel effect.[25]
| Alloying elements | Impurities | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Standard | Limit | Al | Cu | Mg | Pb | Cd | Sn | Fe | Ni | Si | In | Tl |
| Nyrstar | min | 3.8 | 2.5 | 0.4 | - | - | - | - | - | - | - | - |
| max | 4.2 | 3.5 | 0.6 | 0.003 | 0.003 | 0.001 | 0.020 | - | - | - | - | |
| Property | Metric value | Imperial value |
|---|---|---|
| Mechanical properties | ||
| Ultimate tensile strength | < 200 MPa | < 29,000 psi |
| Yield strength (0.2% offset) | < 200 MPa | < 29,000 psi |
| Elongation | < 2% | |
| Hardness | 150 Brinell max | |
| Physical properties | ||
| Solidification range (melting range) | 380—390 °C | 716—734 °F |
| Density | 6.6 g/cm3 | 0.25 lb/in3 |
| Coefficient of thermal expansion | 28.0 μm/m-°C | 15.4 μin/in-°F |
| Thermal conductivity | 105 W/m-K | 729 BTU-in/hr-ft2-°F |
| Electrical conductivity | 25% IACS | |
| Specific heat capacity | 419 J/kg-°C | 0.100 BTU/lb-°F |
| Coefficient of friction | 0.08 | |
Zamak 3
[edit]Zamak 3 is the de facto standard for the zamak series of zinc alloys; all other zinc alloys are compared to this. Zamak 3 has the base composition for the zamak alloys (96% zinc, 4% aluminum). It has excellent castability and long term dimensional stability. More than 70% of all North American zinc die castings are made from zamak 3.[2]
| Alloying elements | Impurities | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Standard | Limit | Al | Cu† | Mg | Pb | Cd | Sn | Fe | Ni | Si | In | Tl |
| ASTM B240[21] (Ingot) | min | 3.9 | - | 0.025 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.1 | 0.05 | 0.004 | 0.003 | 0.002 | 0.035 | - | - | - | - | |
| ASTM B86[22] (Cast) | min | 3.5 | - | 0.025 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.25 | 0.05 | 0.005 | 0.004 | 0.003 | 0.1 | - | - | - | - | |
| EN1774[23] (Ingot) | min | 3.8 | - | 0.035 | - | - | - | - | - | - | - | - |
| max | 4.2 | 0.03 | 0.06 | 0.003 | 0.003 | 0.001 | 0.02 | 0.001 | 0.02 | - | - | |
| EN12844[24] (Cast) | min | 3.7 | - | 0.025 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.1 | 0.06 | 0.005 | 0.005 | 0.002 | 0.05 | 0.02 | 0.03 | - | - | |
| JIS H2201[14] (Ingot) | min | 3.9 | - | 0.03 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.03 | 0.06 | 0.003 | 0.002 | 0.001 | 0.075 | - | - | - | - | |
| JIS H5301[15] (Cast) | min | 3.5 | - | 0.02 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.25 | 0.06 | 0.005 | 0.004 | 0.003 | 0.01 | - | - | - | - | |
| AS1881[26] | min | 3.9 | - | 0.04 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.03 | 0.06 | 0.003 | 0.003 | 0.001 | 0.05 | - | 0.001 | 0.0005 | 0.001 | |
| GB8738-88[12] | min | 3.9 | - | 0.03 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.1 | 0.06 | 0.004 | 0.003 | 0.0015 | 0.035 | - | - | - | - | |
| †Impurity | ||||||||||||
| Property | Metric value | Imperial value |
|---|---|---|
| Mechanical properties | ||
| Ultimate tensile strength | 268 MPa | 38,900 psi |
| Yield strength (0.2% offset) | 208 MPa | 30,200 psi |
| Impact strength | 46 J (56 J aged) | 34 ft-lbf (41 ft-lbf aged) |
| Elongation at Fmax | 3% | |
| Elongation at fracture | 6.3% (16% aged) | |
| Shear strength | 214 MPa | 31,000 psi |
| Compressive yield strength | 414 MPa | 60,000 psi |
| Fatigue strength (reverse bending 5x108 cycles) | 48 MPa | 7,000 psi |
| Hardness | 97 Brinell | |
| Modulus of elasticity | 96 GPa | 14,000,000 psi |
| Physical properties | ||
| Solidification range (melting range) | 381—387 °C | 718—729 °F |
| Density | 6.7 g/cm3 | 0.24 lb/in3 |
| Coefficient of thermal expansion | 27.4 μm/m-°C | 15.2 μin/in-°F |
| Thermal conductivity | 113 W/mK | 784 BTU-in/hr-ft2-°F |
| Electrical resistivity | 6.37 μΩ-cm at 20 °C | 2.51 μΩ-in at 68 °F |
| Latent heat (heat of fusion) | 110 J/g | 4.7x10−5 BTU/lb |
| Specific heat capacity | 419 J/kg-°C | 0.100 BTU/lb-°F |
| Coefficient of friction | 0.07 | |
Zamak 4
[edit]Zamak 4 was developed for the Asian markets to reduce the effects of die soldering while maintaining the ductility of zamak 3. This was achieved by using half the amount of copper from the zamak 5 composition.[27]
| Alloying elements | Impurities | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Standard | Limit | Al | Cu | Mg | Pb | Cd | Sn | Fe | Ni | Si | In | Tl |
| Ningbo Jinyi Alloy Material Co.[13] | min | 3.9 | 0.3 | 0.03 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.5 | 0.06 | 0.003 | 0.002 | 0.002 | 0.075 | - | - | - | - | |
| Property | Metric value | Imperial value |
|---|---|---|
| Mechanical properties[28] | ||
| Ultimate tensile strength | 317 MPa | 46,000 psi |
| Yield strength (0.2% offset) | 221—269 MPa | 32,000—39,000 psi |
| Impact strength | 61 J (7 J aged) | 45 ft-lbf (5 ft-lbf aged) |
| Elongation | 7% | |
| Shear strength | 214—262 MPa | 31,000—38,000 psi |
| Compressive yield strength | 414—600 MPa | 60,000—87,000 psi |
| Fatigue strength (rotary bending 5x108 cycles) | 48—57 MPa | 7,000—8,300 psi |
| Hardness | 91 Brinell | |
| Physical properties[29] | ||
| Solidification range (melting range) | 380—386 °C | 716—727 °F |
| Density | 6.6 g/cm3 | 0.24 lb/in3 |
| Coefficient of thermal expansion | 27.4 μm/m-°C | 15.2 μin/in-°F |
| Thermal conductivity | 108.9—113.0 W/m-K @ 100 °C | 755.6—784.0 BTU-in/hr-ft2-°F @ 212 °F |
| Electrical conductivity | 26-27% IACS | |
| Specific heat capacity | 418.7 J/kg-°C | 0.100 BTU/lb-°F |
Zamak 5
[edit]Zamak 5 has the same composition as zamak 3 with the addition of 1% copper in order to increase strength (by approximately 10%[17]), hardness and corrosive resistance, but reduces ductility.[30] It also has less dimensional accuracy.[30] Zamak 5 is more commonly used in Europe.[2]
| Alloying elements | Impurities | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Standard | Limit | Al | Cu | Mg | Pb | Cd | Sn | Fe | Ni | Si | In | Tl | Zn |
| ASTM B240[21] (Ingot) | min | 3.9 | 0.75 | 0.03 | - | - | - | - | - | - | - | - | |
| max | 4.3 | 1.25 | 0.06 | 0.004 | 0.003 | 0.002 | 0.075 | - | - | - | - | ||
| ASTM B86[22] (Cast) | min | 3.5 | 0.75 | 0.03 | - | - | - | - | - | - | - | - | |
| max | 4.3 | 1.25 | 0.06 | 0.005 | 0.004 | 0.003 | 0.1 | - | - | - | - | ||
| EN1774[23] (Ingot) | min | 3.8 | 0.7 | 0.035 | - | - | - | - | - | - | - | - | |
| max | 4.2 | 1.1 | 0.06 | 0.003 | 0.003 | 0.001 | 0.02 | 0.001 | 0.02 | - | - | ||
| EN12844[24] (Cast) | min | 3.7 | 0.7 | 0.025 | - | - | - | - | - | - | - | - | |
| max | 4.3 | 1.2 | 0.06 | 0.005 | 0.005 | 0.002 | 0.05 | 0.02 | 0.03 | - | - | ||
| JIS H2201[14] (Ingot) | min | 3.9 | 0.75 | 0.03 | - | - | - | - | - | - | - | - | |
| max | 4.3 | 1.25 | 0.06 | 0.003 | 0.002 | 0.001 | 0.075 | - | - | - | - | ||
| JIS H5301[15] (Cast) | min | 3.5 | 0.75 | 0.02 | - | - | - | - | - | - | - | - | |
| max | 4.3 | 1.25 | 0.06 | 0.005 | 0.004 | 0.003 | 0.01 | - | - | - | - | ||
| AS1881[26] | min | 3.9 | 0.75 | 0.04 | - | - | - | - | - | - | - | - | |
| max | 4.3 | 1.25 | 0.06 | 0.003 | 0.003 | 0.001 | 0.05 | - | 0.001 | 0.0005 | 0.001 | ||
| GB8738-88[12] | min | 3.9 | 0.7 | 0.03 | - | - | - | - | - | - | - | - | |
| max | 4.3 | 1.1 | 0.06 | 0.004 | 0.003 | 0.0015 | 0.035 | - | - | - | - | ||
| Property | Metric value | Imperial value |
|---|---|---|
| Mechanical properties | ||
| Ultimate tensile strength | 331 MPa (270 MPa aged) | 48,000 psi (39,000 psi aged) |
| Yield strength (0.2% offset) | 295 MPa | 43,000 psi |
| Impact strength | 52 J (56 J aged) | 38 ft-lbf (41 ft-lbf aged) |
| Elongation at Fmax | 2% | |
| Elongation at fracture | 3.6% (13% aged) | |
| Shear strength | 262 MPa | 38,000 psi |
| Compressive yield strength | 600 MPa | 87,000 psi |
| Fatigue strength (reverse bending 5x108 cycles) | 57 MPa | 8,300 psi |
| Hardness | 91 Brinell | |
| Modulus of elasticity | 96 GPa | 14,000,000 psi |
| Physical properties | ||
| Solidification range (melting range) | 380—386 °C | 716—727 °F |
| Density | 6.7 kg/dm3 | 0.24 lb/in3 |
| Coefficient of thermal expansion | 27.4 μm/m-°C | 15.2 μin/in-°F |
| Thermal conductivity | 109 W/mK | 756 BTU-in/hr-ft2-°F |
| Electrical resistivity | 6.54 μΩ-cm at 20 °C | 2.57 μΩ-in at 68 °F |
| Latent heat (heat of fusion) | 110 J/g | 4.7x10−5 BTU/lb |
| Specific heat capacity | 419 J/kg-°C | 0.100 BTU/lb-°F |
| Coefficient of friction | 0.08 | |
Zamak 7
[edit]Zamak 7 has less magnesium than zamak 3 to increase fluidity and ductility, which is especially useful when casting thin wall components. In order to reduce inter-granular corrosion a small amount of nickel is added and impurities are more strictly controlled.[2]
| Alloying elements | Impurities | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Standard | Limit | Al | Cu† | Mg | Pb | Cd | Sn | Fe | Ni‡ | Si | In | Tl |
| ASTM B240[21] (Ingot) | min | 3.9 | - | 0.01 | - | - | - | - | - | - | - | - |
| max | 4.3 | 0.1 | 0.02 | 0.002 | 0.002 | 0.001 | 0.075 | - | - | - | - | |
| ASTM B86[22] (Cast) | min | 3.5 | - | 0.005 | - | - | - | - | 0.005 | - | - | - |
| max | 4.3 | 0.25 | 0.02 | 0.003 | 0.002 | 0.001 | 0.075 | 0.02 | - | - | - | |
| GB8738-88[12] | min | 3.9 | - | 0.01 | - | - | - | - | 0.005 | - | - | - |
| max | 4.3 | 0.1 | 0.02 | 0.002 | 0.002 | 0.001 | 0.075 | 0.02 | - | - | - | |
| †Impurity ‡Alloying element | ||||||||||||
| Property | Metric value | Imperial value |
|---|---|---|
| Mechanical properties | ||
| Ultimate tensile strength | 285 MPa | 41,300 psi |
| Yield strength (0.2% offset) | 285 MPa | 41,300 psi |
| Impact strength | 58.0 J | 42.8 ft-lbf |
| Elongation at fracture | 14% | |
| Shear strength | 214 MPa | 31,000 psi |
| Compressive yield strength | 414 MPa | 60,000 psi |
| Fatigue strength (reverse bending 5x108 cycles) | 47.0 MPa | 6,820 psi |
| Hardness | 80 Brinell | |
| Physical properties | ||
| Solidification range (melting range) | 381—387 °C | 718—729 °F |
| Coefficient of thermal expansion | 27.4 μm/m-°C | 15.2 μin/in-°F |
| Thermal conductivity | 113 W/m-K | 784 BTU-in/hr-ft2-°F |
| Electrical resistivity | 6.4 μΩ-cm | 2.5 μΩ-in |
| Specific heat capacity | 419 J/kg-°C | 0.100 BTU/lb-°F |
| Casting temperature | 395—425 °C | 743—797 °F |
Uses
[edit]Common uses for zamak alloys include appliances, bathroom fixtures, die cast toys and automotive industry.[32][33][34] Zamak alloys are also used in the manufacture of some firearms such as those from Hi-Point Firearms.[35][36] In World War 2, zamak alloy buttplates were one of three variations common on Canadian and American-made .303 Lee Enfield rifles, particularly during mid-war production.[37]
See also
[edit]References
[edit]- ^ Zamak Latest Status Info, retrieved 2008-03-02
- ^ a b c d e f g h i Diecasting Alloys, retrieved 2008-03-02
- ^ Wanhill, R.J.H.; Hattenberg, T. (May 2005), Corrosion-induced cracking of model train zinc-aluminum die castings (PDF), National Aerospace Laboratory NLR, NLR-TP-2005-205, archived from the original (PDF) on 2011-07-16.
- ^ a b ZL3/ZL0400/ZnAl4 (Zamak 3), retrieved 2008-02-29
- ^ Cocks, E.J.; Walters, B. (1968), A History of the Zinc Smelting Industry in Britain, Harrap, ISBN 0-245-59377-2.
- ^ World wide zinc die casting standards, Nyrstar, retrieved 2008-02-25.
- ^ a b c Now defunct due to standardization of European countries under EN 1774 & EN 12844.
- ^ a b c d e f g h i j k l m n o p ASTM B86-04e2 (PDF), 2004-10-01, retrieved 2008-02-10
- ^ a b c d e f g h i j k l m n o p ASTM B240-98 (PDF), 1998-05-01, retrieved 2008-02-10
- ^ Semiatin, S. L. (2006). ASM Handbook, Volume 14B: Metalworking: Sheet Forming. ASM International. ISBN 978-0-87170-710-9.
- ^ a b c d e f g h i j k l m n o Alloy designation - cross reference table (PDF), archived from the original on 2011-07-08, retrieved 2010-10-31
- ^ a b c d e f g h i GB8738 - Chinese standard: zinc alloys ingots for casting (2006), retrieved 2008-02-27
- ^ a b c d e f g h i ZN-004, archived from the original on 2012-02-10, retrieved 2008-03-01
- ^ a b c d JIS H2201 - Japanese Industrial Standard - Zinc alloy ingot for die casting (1999), retrieved 2008-02-26
- ^ a b c d JIS H5301 - Japanese Industrial Standard - Zinc alloy die casting (1979), retrieved 2008-02-26
- ^ zamak 4 (Alloy 4), retrieved 2008-03-01
- ^ a b c ZL2/ZL0430/ZnAl4Cu3 (Zamak 2), retrieved 2008-02-29
- ^ Husite Engineering - Benefits of Cast Kirksite Tooling, archived from the original on March 1, 2022, retrieved April 19, 2011
- ^ a b Armstrong, Paul J.; Petch, Bill, Cast Kirksite Re-Emerges as RT Approach for Molding Plastics, retrieved 2008-03-15.
- ^ Parker, Dana T. Building Victory: Aircraft Manufacturing in the Los Angeles Area in World War II, p. 86, 119, 120, Cypress, CA, 2013. ISBN 978-0-9897906-0-4.
- ^ a b c d ASTM B240: Standard specification for zinc in ingot form for die casting: chemical composition, retrieved 2008-02-27
- ^ a b c d ASTM B86: Standard specification for zinc die casting: chemical composition, retrieved 2008-02-27
- ^ a b c EN1774 Standard - zinc and zinc alloys - alloys for foundry purposes - ingot and liquid, retrieved 2008-02-27
- ^ a b c EN12844: Standard - zinc and zinc alloys - castings - specification (September 1998), retrieved 2008-02-27
- ^ a b c KS (spin casting alloy), retrieved 2008-03-15
- ^ a b AS1881 - Australia standard - Zinc alloys - casting ingots and casting requirements (1986), retrieved 2008-02-27
- ^ zamak 4 (Alloy 4), retrieved 2008-03-09
- ^ [1]Zinc alloy mechanical characteristics, archived from the original on 2012-02-10, retrieved 2008-03-01
- ^ [2]Zinc alloy physical characteristics, archived from the original on 2012-02-10, retrieved 2008-03-01
- ^ a b c Zinc Die Casting Alloy Guide (PDF), retrieved 2008-02-29
- ^ Zinc Alloy 7; AG40B; Zn-4Al-0.015Mg, retrieved 2008-02-29
- ^ "Zamak is an alloy". Retrieved 2023-08-26.
- ^ "Zamak Alloys in the automotive industry".
- ^ Metals: Zamak, Met-Mex Peñoles S.A., archived from the original on 2008-01-10
- ^ "SW380 - Forgotten Pocket Gun That Should Stay Thataway". 3 April 2019.
- ^ "An Official Journal of the NRA | Pistol-Caliber Pairing: Hi-Point's Affordable Firearms".
- ^ Charles R. Stratton, British Enfield Rifles, Vol 2, North Cape Publications, 1999 and 2003, pages 106-107
External links
[edit]Zamak
View on GrokipediaHistory and Development
Invention and Early Development
Zamak alloys were developed by the New Jersey Zinc Company in the late 1920s as a response to the need for improved zinc-based materials suitable for die casting.[5] The company's metallurgists focused on alloying zinc with elements like aluminum, magnesium, and copper to enhance fluidity and mechanical strength. This was enabled by advancements in producing high-purity zinc (99.99%) through the refluxer refining process, which removed impurities that caused degradation known as "zinc pest" in earlier alloys.[13] These efforts addressed the shortcomings of pure zinc, which exhibited poor castability and low tensile properties, as well as the toxicity concerns associated with leaded zinc alloys previously used in similar applications.[4] This innovation culminated in the patenting of the initial Zamak formulation around 1929, marking a pivotal advancement in non-ferrous metallurgy for industrial casting processes.[5] By the late 1920s and early 1930s, Zamak alloys saw their first widespread commercial production in the United States, primarily through die-casting operations that leveraged the alloy's superior performance over traditional zinc compositions.[14] Initial applications targeted automotive components, such as carburetor parts and trim hardware, and general hardware items like locks and fittings, where the alloy's ease of casting, dimensional stability, and cost-effectiveness provided significant advantages.[13] This period represented a key shift in the industry, as Zamak gradually supplanted leaded zinc alloys, reducing health risks while enabling more complex and precise part production.[4] The alloys' adoption expanded internationally following licensing agreements, with early entry into Europe via Morris Ashby in Britain during the early 1930s, despite challenges with sourcing high-purity zinc.[15] Post-World War II, production and application grew substantially across Europe, driven by reconstruction efforts and the increasing demand for durable, lightweight materials in automotive and consumer goods sectors, solidifying Zamak's role in global manufacturing.[4]Naming and Etymology
The name "Zamak" is an acronym derived from the German names of the alloy's primary constituent elements: Z for Zink (zinc), A for Aluminium (aluminum), Ma for Magnesium (magnesium), and K for Kupfer (copper).[7][16] This linguistic construction reflects the alloy's composition and was chosen to emphasize its zinc base while highlighting the key alloying elements.[5] The term was introduced in 1929 by the New Jersey Zinc Company, which developed and patented the Zamak family of alloys as a branded product for die-casting applications.[13][5] Initially, alternative names such as "Zama" or "Mazak" were considered during the alloy's early formulation in the 1920s, but "Zamak" was selected to underscore the prominence of zinc as the primary metal.[5] Over time, "Zamak" evolved from a proprietary trademark into a generic term widely used in industry to refer to zinc-aluminum die-casting alloys, regardless of manufacturer.[17] This shift occurred as the alloys gained popularity and standardization, with the name becoming synonymous with the broader category of similar compositions.[16]Composition and Alloying
Base Composition
Zamak alloys are characterized by a base composition dominated by zinc, which constitutes 95-96% by weight, and a fixed aluminum content of 3.5-4.5%, providing the eutectic structure essential for die-casting applications.[18] This aluminum level, nominally 4%, differentiates Zamak alloys from the ZA family, which feature higher aluminum concentrations ranging from 8% to 27% for enhanced strength at the expense of castability.[18] Minor alloying elements include 0–3% copper (Cu) and 0.02-0.05% magnesium (Mg), which are intentionally added in controlled amounts across the family.[18] Impurities are rigorously limited to ensure performance and corrosion resistance, with maximum levels of iron (Fe) at 0.1%, lead (Pb) at 0.005%, cadmium (Cd) at 0.005%, and tin (Sn) at 0.003%.[18] The fundamental chemical makeup of Zamak can be approximated by the formula , where and represent the variable but minimal contributions of copper and magnesium in the base form.[18]Role of Alloying Elements
Zamak alloys consist of zinc as the primary matrix metal, with deliberate additions of aluminum, copper, and magnesium serving distinct functional roles in enhancing the overall performance of the material.[18] Aluminum, typically incorporated at around 4%, plays a crucial role in improving the alloy's castability and fluidity during the die-casting process by lowering the melting point and facilitating better flow into intricate molds.[19] It also contributes to corrosion resistance by promoting the formation of a stable oxide layer on the surface, which acts as a protective barrier against environmental degradation.[20] Furthermore, aluminum refines the microstructure through the formation of a near-eutectic Zn-Al composition, optimizing the melting range to approximately 380-420°C for efficient processing.[19] Copper, added in amounts of 0–3%, primarily enhances the mechanical integrity of the alloy by increasing tensile strength and hardness, making it suitable for applications requiring durability under load.[18] However, excessive copper beyond 3% can diminish ductility, leading to reduced flexibility and potential brittleness in the final product.[18] This element also supports improved wear resistance, particularly in components exposed to frictional stresses.[21] Magnesium, present in trace levels of 0.02-0.05%, is essential for mitigating intergranular corrosion by refining grain boundaries and preventing the propagation of corrosive attacks along them.[22] It further stabilizes dimensional accuracy during and after casting by controlling shrinkage and minimizing long-term creep deformation.[2] Control of impurities is vital to maintain the alloy's integrity; for instance, iron levels are strictly limited to prevent the formation of brittle intermetallic compounds that could compromise toughness.[23] Similarly, low concentrations of lead, cadmium, and tin are enforced to avoid environmental hazards and to prevent issues like hot shortness or cracking during solidification, ensuring compliance with regulatory standards.[22]Properties
Mechanical Properties
Zamak alloys are known for their balanced mechanical properties, offering sufficient strength and ductility for die-cast components in applications such as automotive hardware, consumer electronics, and fasteners. These properties arise from the zinc-based matrix reinforced by aluminum and copper additions, enabling good formability while maintaining structural integrity under load. Typical tensile strength ranges from 280 to 380 MPa across common grades, providing a robust yet lightweight alternative to ferrous metals in non-structural roles.[24] Ductility is assessed through elongation at break, which typically falls between 3% and 10%, allowing Zamak alloys to withstand moderate deformation without brittle failure. This range reflects variations in alloy composition and casting conditions, with higher elongation in low-copper variants suited for parts requiring impact resistance.[24][25] Hardness, measured on the Brinell scale, generally spans 80 to 120 HB, with higher values correlated to increased copper content that enhances wear resistance. This makes Zamak suitable for sliding or abrasive contacts, though excessive copper can promote aging-related shifts in properties.[24] Fatigue strength, critical for cyclic loading in load-bearing parts, is approximately 50 to 60 MPa at 5×10^8 cycles under reverse bending conditions, demonstrating endurance for applications like hinges and brackets.[24] Natural aging in Zamak alloys involves precipitate formation from supersaturated elements, which can initially increase tensile strength by up to 20-30% through hardening mechanisms, though prolonged aging often reduces ductility and may stabilize or slightly diminish overall strength after one year. This process underscores the importance of timely use or stabilization treatments for dimensional and performance consistency.[25]| Property | Typical Range | Notes |
|---|---|---|
| Tensile Strength | 280-380 MPa | Varies by grade; higher in copper-rich variants like Zamak 2 and 5. |
| Elongation at Break | 3-10% | Indicates ductility; decreases with aging in some cases. |
| Hardness (Brinell) | 80-120 HB | Influenced by Cu content; affects machinability and wear. |
| Fatigue Strength | 50-60 MPa (at 5×10^8 cycles) | Suitable for moderate cyclic loads; tested in reverse bending. |
