The traditional die-cast zinc alloys have No. 2, 3, 4, 5, and 7 alloys, and the most widely used at present is the No. 3 zinc alloy. In the 1970s, high-aluminum zinc-based alloys ZA-8, ZA-12, and ZA-27 were developed.
Zamak 3: Good flow and mechanical properties.
Applied to castings with low mechanical strength requirements, such as toys, lamps, decorations, and some electrical devices.
Zamak 5: Good flow and good mechanical properties.
Applied to castings with certain mechanical strength requirements, such as auto parts, mechanical and electrical parts, mechanical parts, and electrical components.
Zamak 2: For mechanical parts with special requirements for mechanical properties, high hardness requirements, good wear resistance and dimensional accuracy.
ZA8: Good impact strength and dimensional stability, but poor fluidity.
It is used for workpieces with small size, precision and mechanical strength, such as electrical components.
Superloy: The best liquidity for die-casting thin-walled, large-size, high-precision, complex-shaped workpieces, such as electrical components and their boxes.
Different zinc alloys have different physical and mechanical properties, which provides a space for die casting designs.
According to the manufacturing process, zinc alloys can be divided into two categories: cast zinc alloys and deformed zinc alloys. The yield of cast alloys is much greater than that of deformed alloys. The following table lists the composition, properties, and uses of several important zinc alloys.
Cast zinc alloys are divided into diecast zinc alloys (solidified under applied pressure) and gravity cast zinc alloys (solidified only by gravity) depending on the casting method.
Pressure Casting of Zinc Alloys Since the alloy was used in the automotive industry in 1940, production has increased dramatically. About 25% of the total zinc consumed is used to produce this alloy. Advanced and applicable technologies are constantly being adopted and developed rapidly. Corresponding talents are also increasing, and there are steel excellence networks. The most commonly used alloy is Zn-Al-Cu-Mg. Some impurities significantly affect the performance of die-cast zinc alloys. Therefore, the content of iron, lead, cadmium, tin and other impurities is very strict, and their upper limits are 0.005%, 0.004%, 0.003%, and 0.02%, respectively. Therefore, high-purity zinc with a purity greater than 99.99% should be used as the raw material for die-cast zinc alloys.
Gravity casting zinc alloys can be cast in sand molds, plaster molds, or hard molds. This kind of zinc alloy not only has the characteristics of general die-casting zinc alloy, but also has high strength and good casting performance. The cooling rate has no obvious influence on the mechanical properties. Residues and wastes can be recycled, the gate is simple, and it is not sensitive to overheating and remelting. The rate is small, the porosity is small, the electroplating can be performed, and the finishing can be done by conventional methods.
Deformed zinc alloys Industrially applied deformed zinc alloys In addition to traditional varieties, Zn-1Cu-0.1Ti and Zn-22Al alloys have emerged. After rolling the former alloy, due to TiZn15 intermetallic compounds, the dispersed particles line up in the rolling direction, which can prevent the grain boundary from moving.
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