Material Information
Zinc is one of the most versatile and widely used metals in die casting. It offers several advantages that make it an excellent choice for producing high-precision components with complex geometries. Here are some key points about zinc casting metals:
Zinc alloy characteristics
• Complexe Shape
• Tight Tolerances
• Thinner Walls
• Faster Production
• Longer Tool Life
• Easy Finishing
• Environmentally Friendly
Zinc, although heavier than other metals, can be a superior option when it comes to strength and durability. And it can be more a cost effective option too. Zinc has a higher melting point than other metals — which means it uses less energy during the manufacturing process. Many manufacturers find die casting in zinc to be the ideal alternative to machined, pressed, stamped, and fabricated components.
Applications for Zinc
• Complex net-shaped zinc housings, with precise thin walls offer excellent electrical performance and shielding properties.
• Our proprietary multi-slide die casting process and superior thin-wall capabilities make us the foremost supplier of zinc components for broad range of consumer electronic devices.
• The castability of zinc, its wear resistance, and structural integrity make it perfect for the creation of the multi-faceted, highly complex shapes used in automotive safety and electronics industry.
Casting Process
Zinc is typically cast using the hot chamber die casting process, which allows for fast production cycles and the ability to cast intricate details with close dimensional tolerances.
The process involves a gooseneck submerged in molten metal, with a vertical plunger driving the metal into the die under high pressure.
Zinc That STK Offers
Zamak2
Zinc Alloy 2, also known as Kirksite or Zamak 2 (ASTM AC43A), is the highest strength and hardness of the Zamak family.
Zamak3
Zamak 3 (ASTM AG40A), or Zinc Alloy 3, is the most widely used zinc alloy in North America and is usually the first choice when considering zinc for die casting for a number of reasons.
Zamak5
Zamak 5 (ASTM AC41A) or Zinc Alloy 5, is the most widely used zinc alloy in Europe.
Zamak7
Zamak 7 (ASTM AG40B), or Zinc Alloy 7, is a modification of Zamak 3. It is a high-purity alloy containing lower magnesium content and has a tighter impurities specification. This results in improved casting fluidity, ductility and surface finish.
Za8
ZA-8, or zinc aluminum alloy, contains significantly more aluminum than the Zamak group of alloys. ZA-8 contains approximately 8.4% aluminum and is the only ZA alloy that can be hot-chamber die cast, an important consideration when selecting a material for a component.
AcuZinc5
ACuZinc5 is an alloy researched and developed by General Motors. It is best known for its creep performance, surface hardness, and lubricity.
EZAC
EZAC is a hot-chamber zinc die casting alloy with superior creep resistance, high yield strength, and high hardness.
ZA 27 - Zinc Aluminum
ZA-27, or zinc aluminum alloy, contains significantly more aluminum than the Zamak group of alloys. The number 27 represents the approximate percentage of aluminum.
Zinc Alloy Chemical Composition
MECHANICAL PROPERTIES |
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| Alloy | Elogngation (%in 50mm) | Tensile Strength (MPa) | Yield Strength (MPa) | Impact Strength (J) | Shear Strength (MPa) | Hardness (Brinell HB) | Process |
| Zamak 2 | 7 | 359 | 283 | 47 | 317 | 100 | Hot Chamber Die Casting |
| Zamak 3 | 10 | 283 | 221 | 58 | 214 | 82 | Hot Chamber Die Casting |
| Zamak 5 | 7 | 328 | 228 | 65 | 262 | 91 | Hot Chamber Die Casting |
| Zamak 7 | 13 | 283 | 221 | 58 | 214 | 80 | Hot Chamber Die Casting |
| ZA 8 | 10 | 374 | 290 | 42 | 275 | 103 | Hot Chamber Die Casting |
| EZAC | 6.7 | 414 | 393 | - | - | - | Hot Chamber Die Casting |
COMPOSITION |
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| % | Zamak 2 | Zamak 3 | Zamak 5 | Zamak 7 | ZA 8 |
| Aluminum | 3.5-4.3 | 3.5-4.3 | 3.5-4.3 | 3.5-4.3 | 8.0-8.8 |
| Copper | 2.5-3.0 | 0.25 | 0.75-1.25 | 0.25 | 0.8-1.3 |
| Magnesium | 0.02-0.05 | 0.02-0.05 | 0.03-0.08 | 0.005-0.02 | 0.015-0.03 |
| Iron(max) | 0.1 | 0.1 | 0.1 | 0.075 | 0.075 |
| Lead (max) | 0.005 | 0.005 | 0.005 | 0.003 | 0.006 |
| Cadmium (Max) | 0.004 | 0.004 | 0.004 | 0.002 | 0.006 |
| Tin(max) | |||||
| Zinc | Bal. | Bal. | Bal. | Bal. | Bal. |
| RoHS Compliant | Yes | Yes | Yes | Yes | Yes |
PHYSICAL PROPERTIES |
||||||
| Alloy | Density (g/cm3) | Melting Point (Average +/-50℃) | Thermal Conductivity (W/m K) | Coefficient of Thermal Expansion (μm/m°K) | Electrical Conductivity (% IACS) | process |
| Zamak 2 | 6.6 | 385 | 105 | 27.7 | 25 | Hot Chamber Die Casting |
| Zamak 3 | 6.6 | 384 | 113 | 27.4 | 27 | Hot Chamber Die Casting |
| Zamak 5 | 6.6 | 383 | 109 | 27.4 | 26 | Hot Chamber Die Casting |
| Zamak 7 | 6.6 | 384 | 113 | 27.4 | 27 | Hot Chamber Die Casting |
| ZA 8 | 6.3 | 390 | 115 | 23.3 | 27.7 | Hot Chamber Die Casting |
| EZAC | 6.49 | 396 | - | - | - | Hot Chamber Die Casting |
Zinc Surface Finishing
The surface treatment of zinc alloys help to enhance its appearance aesthetics, corrosion resistance and wear resistance and other properties.
Our zinc surface finishing includes, but is not limited to:
• Powder Coating
• Wet Paint
• Bright/Matt Chrome Plating
• Black and variegated electroplating
• NickelPlating
• Gold Plating
• Sandblasting
• PVD Coating
• Laser engraving
Aluminum castings are lightweight and able to withstand the highest operating temperatures of all die cast alloys.
Aluminum Alloy Characteristics
• Lightweight & Durable
• Good Strength-to-Weight Ratio
• Great Resistance to Corrosion
• Excellent Electrical Conductivity
• Fully Recyclable and Reusable in Production
• High Operating Temperatures
Aluminum’s strength, corrosion resistance, and heat dissipating properties offer mechanical designers significant advantages. And our proprietary Thin Wall Aluminum Technology has made aluminum die casting an option for even more applications.
Aluminum Alloys That STK Offers
Aluminum Alloy A380
A380 is one of the most commonly specified aluminum alloys with a number of significant benefits
Aluminum Alloy 383 (ADC12)
If your component is highly intricate, 383—also known as ADC12 in Asia—is often used as an alternative to A380.
B390
B390 is an aluminum alloy with high hardness and good wear resistance.
A413
A413 is an aluminum alloy with excellent pressure tightness.
413
413 is an Aluminum based alloy that is used for die casting parts.
K-Alloy
K-Alloy is an aluminum, cold-chamber die cast alloy that was engineered to protect components against harsh operating environments.
A360
A360 is an aluminum alloy with excellent pressure tightness and fluidity.
Aluminum Alloy Chemical Composition-JIS & ASTM Standard
ALUMINUM ALLOY INGOT CHEMICAL COMPOSITION |
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| JIS H2118:2000 | Cu | Si | Mg | Zn | Fe | Mn | Ni |
| ADC1(AD1.1) | 1.00Max | 11.0-13.0 | 0.30Max | 0.50Max | 0.9Max | 0.30Max | 0.50Max |
| ADC3(AD3.1) | 0.60Max | 9.0-10.0 | 0.45-0.60 | 0.50Max | 0.90Max | 0.30Max | 0.50Max |
| ADC5(AD5.1) | 0.20Max | 0.30Max | 4.1-8.5 | 0.10Max | 1.10Max | 0.30Max | 0.10Max |
| ADC6(AD6.1) | 0.10Max | 1.00Max | 2.6-4.0 | 0.40Max | 0.60Max | 0.4-0.6 | 0.10Max |
| ADC10(AD10.1) | 2.0-4.0 | 7.5-9.5 | 0.30Max | 1.00Max | 0.9Max | 0.50Max | 0.50Max |
| ADC10Z(AD10Z.1) | 2.0-4.0 | 7.5-9.5 | 0.30Max | 3.00Max | 0.9Max | 0.50Max | 0.50Max |
| ADC12(AD12.1) | 1.5-3.5 | 9.6-12.0 | 0.30Max | 1.00Max | 0.9Max | 0.50Max | 0.50Max |
| ADC12Z(AD12Z.1) | 1.5-3.5 | 9.6-12.0 | 0.30Max | 3.00Max | 0.9Max | 0.50Max | 0.50Max |
| ADC14(AD14.1) | 4.0-5.0 | 16.0-18.0 | 0.50-0.65 | 1.50Max | 0.9Max | 0.50Max | 0.30Max |
ALUMINUM ALLOY INGOT CHEMICAL COMPOSITION |
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| ASTM B85-96 | Cu | Si | Mg | Zn | Fe | Mn | Ni |
| A356.1 | 0.25Max | 6.5-7.5 | 0.25-0.45 | 0.35Max | 0.50Max | 0.35Max | - |
| A356.2 | 0.10Max | 6.5-7.5 | 0.30-0.45 | 0.05Max | 0.12Max | 0.05Max | - |
| A360 | 0.60Max | 9.0-10.0 | 0.4-0.6 | 0.50Max | 1.30Max | 0.35Max | 0.50Max |
| A360.1 | 0.60Max | 9.0-10.0 | 0.45-0.6 | 0.40Max | 1.00Max | 0.35Max | 0.50Max |
| A380.0 | 3.0-4.0 | 7.5-9.5 | 0.30Max | 3.00Max | 1.30Max | 0.50Max | 0.50Max |
| A380.1 | 3.0-4.0 | 7.5-9.5 | 0.10Max | 2.90Max | 1.00Max | 0.50Max | 0.50Max |
| A383 | 2.0-3.0 | 9.5-11.5 | 0.10Max | 3.00Max | 1.30Max | 0.50Max | 0.50Max |
| A413.1 | 1.00Max | 11.0-13.0 | 0.10Max | 0.40Max | 1.00Max | 0.35Max | 0.50Max |
| A413.2 | 0.10Max | 11.0-13.0 | 0.05Max | 0.05Max | 0.60Max | 0.05Max | 0.05Max |
ALUMINUM Surface Finishing
STK will manage customer finishing requirements to ensure parts meet specifications in both a timely and cost-effective manner.
Our aluminum surface finishing includes, but is not limited to:
• Powder Coating (electrostatic application)
• Wet Paint
• Chromate
• E-Coat
• Electroless Nickel
• Chrome
Gravity casting, also known as permanent mold casting, is a widely used process for producing high-quality metal parts. When it comes to zinc casting metals, this method offers several advantages and unique characteristics. Here are some key points about gravity casting of zinc casting metals:
Process Overview:
In gravity casting, molten zinc is poured into a mold using the force of gravity, without the need for external pressure.
This method is suitable for producing parts with complex geometries and fine details.
Advantages:
• Excellent Fluidity: Zinc alloys have excellent casting fluidity, which allows for the production of intricate and detailed parts.
• Good Surface Finish: Gravity casting of zinc results in parts with smooth surfaces, reducing the need for extensive post-casting machining.
• Dimensional Accuracy: The process provides high dimensional accuracy, making it ideal for precision components.
• Cost-Effective: Reusable molds reduce tooling costs.
• Sustainability: The molds can be used repeatedly, minimizing waste.
Zinc Alloys Used:
Common zinc alloys used in gravity casting include Zamak 3, Zamak 5, and ZA-83.
Zamak 3 is known for its excellent castability and finishing characteristics, while ZA-8 offers additional strength and creep resistance.
Applications:
Gravity-cast zinc parts are used in various industries, including automotive, electronics, and decorative hardware.
Typical products include housings, brackets, and intricate decorative items.
Considerations:
Mold Material: The choice of mold material (e.g., sand, metal, or ceramic) can affect the quality and properties of the final product.
Cooling Rate: Proper control of the cooling rate is essential to minimize defects and ensure the desired mechanical properties.
Zinc Alloy Chemical Composition
MECHANICAL PROPERTIES |
|||||||
| Alloy | Elogngation (%in 50mm) | Tensile Strength (MPa) | Yield Strength (MPa) | Impact Strength (J) | Shear Strength (MPa) | Hardness (Brinell HB) | Process |
| Zamak 2 | 7 | 359 | 283 | 47 | 317 | 100 | Gravity Die Casting |
| Zamak 3 | 10 | 283 | 221 | 58 | 214 | 82 | Gravity Die Casting |
| Zamak 5 | 7 | 328 | 228 | 65 | 262 | 91 | Gravity Die Casting |
| Zamak 7 | 13 | 283 | 221 | 58 | 214 | 80 | Gravity Die Casting |
| ZA 8 | 10 | 374 | 290 | 42 | 275 | 103 | Gravity Die Casting |
| EZAC | 6.7 | 414 | 393 | - | - | - | Gravity Die Casting |
COMPOSITION |
|||||
| % | Zamak 2 | Zamak 3 | Zamak 5 | Zamak 7 | ZA 8 |
| Aluminum | 3.5-4.3 | 3.5-4.3 | 3.5-4.3 | 3.5-4.3 | 8.0-8.8 |
| Copper | 2.5-3.0 | 0.25 | 0.75-1.25 | 0.25 | 0.8-1.3 |
| Magnesium | 0.02-0.05 | 0.02-0.05 | 0.03-0.08 | 0.005-0.02 | 0.015-0.03 |
| Iron(max) | 0.1 | 0.1 | 0.1 | 0.075 | 0.075 |
| Lead (max) | 0.005 | 0.005 | 0.005 | 0.003 | 0.006 |
| Cadmium (Max) | 0.004 | 0.004 | 0.004 | 0.002 | 0.006 |
| Tin(max) | |||||
| Zinc | Bal. | Bal. | Bal. | Bal. | Bal. |
| RoHS Compliant | Yes | Yes | Yes | Yes | Yes |
PHYSICAL PROPERTIES |
||||||
| Alloy | Density (g/cm3) | Melting Point (Average +/-50℃) | Thermal Conductivity (W/m K) | Coefficient of Thermal Expansion (μm/m°K) | Electrical Conductivity (% IACS) | process |
| Zamak 2 | 6.6 | 385 | 105 | 27.7 | 25 | Gravity Die Casting |
| Zamak 3 | 6.6 | 384 | 113 | 27.4 | 27 | Gravity Die Casting |
| Zamak 5 | 6.6 | 383 | 109 | 27.4 | 26 | Gravity Die Casting |
| Zamak 7 | 6.6 | 384 | 113 | 27.4 | 27 | Gravity Die Casting |
| ZA 8 | 6.3 | 390 | 115 | 23.3 | 27.7 | Gravity Die Casting |
| EZAC | 6.49 | 396 | - | - | - | Gravity Die Casting |
Zinc Surface Finishing
The surface treatment of zinc alloys help to enhance its appearance aesthetics, corrosion resistance and wear resistance and other properties. Our zinc surface finishing includes, but is not limited to:
• Powder Coating
• Wet Paint
• Bright/Matt Chrome Plating
• Black and variegated electroplating
• NickelPlating
• Gold Plating
• Sandblasting
• PVD Coating
• Laser engraving
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