diecasting zinc alloy specifications - english

Zinc Alloy SpecificAtionS for

Diecasting

The Brock Metal Company Limited

The Brock MetalCompany Limited

As one of the leading suppliers of primary Zinc alloys throughout Europe, The Brock Metal Company Limited has an unrivalled reputation for metal quality, technical support and service.

We specialise in the supply of alloys to the diecasting and galvanising industries, producing over 25,000 tonnes of primary zinc alloys per annum and supplying 25 countries across europe and the world.

to manufacture a consistent diecast component requires total confidence in the quality and consistency of the alloy used. the track record, systems and traceability at Brock Metal are second to none and ensure the highest level of confidence in our products at the design, specification and production stages.

All of our Zinc alloys conform to en 1774 1998 and are manufactured from primary or virgin Zinc conforming to SHG (Super High Grade) or Zn1 grades which are 99.995% pure and themselves conform to international specifications such as en1179. our quality assurance systems are fully accredited to iSo 9001.

As well as the more generally available diecasting and foundry zinc alloys, Brock Metal also produces a number of specialist diecasting alloys. Brock Metal can also make alloys to special chemistries to meet specific customer requirements.

Unlike other metals, a number of generic terms for zinc alloys have developed which still leads to considerable confusion to product designers and specifiers, so we strongly encourage the identification of alloys through the relevant en or International standard classifications listed in this booklet.

Walsall road, norton canes, cannock, Staffordshire, WS11 9nr. United Kingdom.tel: +44 (0) 1543 276666 email: [email protected] www.brockmetal.com

INGOT &PACK SIZES

STANDARD INGOTS AND PACKS

Standard Ingot - 7Kg nominal weightAvailable in ZL3, ZL5, ZL7, ZL7+

Alloy designation number 3 or 5.

45mm15mm

Standard Feeder bar or hooked ingot - 7Kg nominal weight

Standard pack on legs - As drawn 1000kg nominal or 530kg at 410mm highAvailable for supply ZL3 and ZL5, supplied banded and plastic wrapped.

580mm580mm

Standard slotted pack - 750kgs as drawn or 1000kgs at 700mm highAvailable for ZL2, ZL3, ZL5 - hooked feeder bar ingotsSupplied banded and plastic wrapped

560mm560mm

Standard pack on wooden pallet - 1000kgAvailable for supply ZL2, ZL3, ZL5, Standard ingot and hooked or feeder bar ingot.

SPECIAL ALLOYS

INGOT &PACK SIZES

600mm 600mm

Standard Ingot Pack - 24Kg Ingot - 1000Kg

Side line ingot pack - available in G5 galvanizing alloys and other alloys on request.Nominal pack weight - 1000Kgs. Supplied - Banded wrapped on wooden pallets.

227mm 145mm

R 5.0 mm R 2.0 mm

34mm85mm

114mm158mm

600/605mm

24kg Ingot

470mm160mm

15kg Notched Ingot

1430mm

1100mm

90mm dia min

Zn Al Galvanising alloy blocks- available chemistries

INGOT &PACK SIZES

STANDARD INGOTS AND PACKS

Standard Ingot - 7Kg nominal weightAvailable in ZL3, ZL5, ZL7, ZL7+

Alloy designation number 3 or 5.

45mm15mm

Standard Feeder bar or hooked ingot - 7Kg nominal weight

Standard pack on legs - As drawn 1000kg nominal or 530kg at 410mm highAvailable for supply ZL3 and ZL5, supplied banded and plastic wrapped.

580mm580mm

Standard slotted pack - 750kgs as drawn or 1000kgs at 700mm highAvailable for ZL2, ZL3, ZL5 - hooked feeder bar ingotsSupplied banded and plastic wrapped

560mm560mm

Standard pack on wooden pallet - 1000kgAvailable for supply ZL2, ZL3, ZL5, Standard ingot and hooked or feeder bar ingot.

SPECIAL ALLOYS

INGOT &PACK SIZES

600mm 600mm

Standard Ingot Pack - 24Kg Ingot - 1000Kg

Side line ingot pack - available in G5 galvanizing alloys and other alloys on request.Nominal pack weight - 1000Kgs. Supplied - Banded wrapped on wooden pallets.

227mm 145mm

R 5.0 mm R 2.0 mm

34mm85mm

114mm158mm

600/605mm

24kg Ingot

470mm160mm

15kg Notched Ingot

1430mm

1100mm

90mm dia min

Zn Al Galvanising alloy blocks- available chemistries

PRESSURE DIE CASTING AND TOOLING ALLOY

ZL-2ZL2 is a Zinc based alloy which conformsto EN 1774 1997 Ingot Specification andwhich can be used for pressure die castcomponents or gravity cast specialisedtooling. It is one of a family of versatilehigh grade zinc alloys manufactured byBrock Metal.ApplicationPressure DiecastZL2 is used selectively for small castings whereimproved as cast tensile strength or hardness arerequired. Its dimensional stability and retention ofmechanical properties over a period of years orwhen subject to higher service temperatures arenot as good as ZL3 or ZL5. It has excellentfluidity during casting

Gravity Cast.ZL2 in the gravity cast condition, in sand orplaster moulds is ideal for use in suchapplications as press forming tools, rubbermoulds, blow moulding tools and plastic injectionmoulding inserts because of its excellentmechanical and physical properties. Being easilycastable with a constant solidification shrinkage,tools and moulds can be cast to closedimensional tolerances requiring only a minimumof machining.

ZL2 tooling can be produced easily and quicklyand has a long operational life. Redundant toolingcan be reclaimed providing there is nocontamination. However, since the level ofimpurities allowed are very low, specialistknowledge is required. You are advised to contactBrock Metal who provide a reclaiming service.

When designing a stressed component using ZL2further reference should be made to the alloysproperties, at elevated temperatures, after naturalor artificial ageing and the alloys creep properties.

Min MaxAluminium 3.8% 4.2%Copper 2.7% 3.3%Magnesium 0.035% 0.06%Zinc Remainder

Iron - 0.020%Lead - 0.003%Cadmium - 0.003%Tin - 0.001%Nickel - 0.001%Silicon - 0.02%

Pressure GravityDie Cast Cast

CastingTemperature 0C 425-435 400-440Freezing Range 0C 378-390Specific Heat J/gk 0.4187

- (0.10)Solidification Cm/m 1.08Shrinkage (in/ft) (0.13)Casting Shrinkage Mm/mm 0.006 -

(in/in) (0.006) -Thermal Conductivity W/m0C 105at 180C (C.G.S) (0.25)Thermal Expansion - 28x106

Linear per 0C

Alloy Composition

Impurities

Electrical Conductivity %age 26at 200C IACSSpecific Gravity - 6.8Density Kg/m3 6,700

(ib/in3) (0.24)Tensile Strength at N/mm2 338 232200C (ib/in2) (49,000) (33,600)Elongation at 200C %in 2in 8 1.60Impactstrengthat200C J 46.8 2.4(unnotchedsamples) (ft.obf) (34.5) (1.80)Hardness BHN 100 109CompressiveStrength N/mm2 641 773

(lbf/in2) 93 (112,200)

Typical as cast physical and mechanical properties

Figures relate to material in casting form. Properties vary for different processes. Further data available in the technical resource area on brockmetal.com

PRESSURE DIE CASTING ALLOY

ZL3 is a hot chamber pressure die castingzinc base alloy which conforms to EN1774 1997 Ingot Specification and is oneof a family of versatile high grade zincalloys manufactured by Brock Metal.Application

ZL3 is a general-purpose alloy and is primarilyused for producing castings for a variety ofapplications on a hot chamber pressure diecasting machine. The alloy’s mechanical andphysical properties make it ideal for use incastings for the engineering and automotiveindustry, household equipment and utensils,office equipment, builders hardware, locks, toys,giftware etc. ZL3 is easily machined, buffed,polished, lacquered and electroplated fordecorative or functional purposes.

National Specifications

The composition of ZL3 conforms to the currentEN 1774 1997 Standard, which is now commonto all EU countries.

When designing a stressed component usingZL3 further reference should be made to thealloys properties, at elevated temperatures, afternatural or artificial ageing and the alloys creepproperties.

Min MaxAluminium 3.8% 4.2%Magnesium 0.035% 0.06%Zinc Remainder

Iron - 0.020%Copper - 0.03%Lead - 0.003%Cadmium - 0.003%Tin - 0.001%Nickel - 0.001%Silicon - 0.02%

CastingTemperature 0C 405-425Freezing Range 0C 382-387Specific Heat J/gk 0.4187

- (0.10)Solidification Cm/m 1.17Shrinkage (in/ft) (0.14)Casting Shrinkage Mm/mm 0.006

(in/in) (0.006)Thermal Conductivity W/m0C 113at 180C (C.G.S) (0.27)Thermal Expansion - 28x106

Linear per 0C

Alloy Composition

Impurities

Electrical conductivity%age IACS 26at 200C

Specific Gravity - 6.7Density Kg/m3 6,700

(lb/in3) (0.24)Tensile Strength N/mm2 283-241at 200C (lbf/in2) (41,000)Elongation at 200C %in 2in 10-16%Impact strength at at 200C J 56.9(unnotched samples) (ft.obf) (42)Hardness BHN 82-87

PRESSURE DIE CASTING AND TOOLING ALLOY

ZL-2ZL2 is a Zinc based alloy which conformsto EN 1774 1997 Ingot Specification andwhich can be used for pressure die castcomponents or gravity cast specialisedtooling. It is one of a family of versatilehigh grade zinc alloys manufactured byBrock Metal.ApplicationPressure DiecastZL2 is used selectively for small castings whereimproved as cast tensile strength or hardness arerequired. Its dimensional stability and retention ofmechanical properties over a period of years orwhen subject to higher service temperatures arenot as good as ZL3 or ZL5. It has excellentfluidity during casting

Gravity Cast.ZL2 in the gravity cast condition, in sand orplaster moulds is ideal for use in suchapplications as press forming tools, rubbermoulds, blow moulding tools and plastic injectionmoulding inserts because of its excellentmechanical and physical properties. Being easilycastable with a constant solidification shrinkage,tools and moulds can be cast to closedimensional tolerances requiring only a minimumof machining.

ZL2 tooling can be produced easily and quicklyand has a long operational life. Redundant toolingcan be reclaimed providing there is nocontamination. However, since the level ofimpurities allowed are very low, specialistknowledge is required. You are advised to contactBrock Metal who provide a reclaiming service.

When designing a stressed component using ZL2further reference should be made to the alloysproperties, at elevated temperatures, after naturalor artificial ageing and the alloys creep properties.

CastingTemperature 0C 425-435 400-440Freezing Range 0C 378-390Specific Heat J/gk 0.4187

- (0.10)Solidification Cm/m 1.08Shrinkage (in/ft) (0.13)Casting Shrinkage Mm/mm 0.006 -

(in/in) (0.006) -Thermal Conductivity W/m0C 105at 180C (C.G.S) (0.25)Thermal Expansion - 28x106

Linear per 0C

Alloy Composition

Impurities

Electrical Conductivity %age 26at 200C IACSSpecific Gravity - 6.8Density Kg/m3 6,700

(ib/in3) (0.24)Tensile Strength at N/mm2 338 232200C (ib/in2) (49,000) (33,600)Elongation at 200C %in 2in 8 1.60Impactstrengthat200C J 46.8 2.4(unnotchedsamples) (ft.obf) (34.5) (1.80)Hardness BHN 100 109CompressiveStrength N/mm2 641 773

(lbf/in2) 93 (112,200)

ZL3 is a hot chamber pressure die castingzinc base alloy which conforms to EN1774 1997 Ingot Specification and is oneof a family of versatile high grade zincalloys manufactured by Brock Metal.Application

ZL3 is a general-purpose alloy and is primarilyused for producing castings for a variety ofapplications on a hot chamber pressure diecasting machine. The alloy’s mechanical andphysical properties make it ideal for use incastings for the engineering and automotiveindustry, household equipment and utensils,office equipment, builders hardware, locks, toys,giftware etc. ZL3 is easily machined, buffed,polished, lacquered and electroplated fordecorative or functional purposes.

The composition of ZL3 conforms to the currentEN 1774 1997 Standard, which is now commonto all EU countries.

Iron - 0.020%Copper - 0.03%Lead - 0.003%Cadmium - 0.003%Tin - 0.001%Nickel - 0.001%Silicon - 0.02%

(in/in) (0.006)Thermal Conductivity W/m0C 113at 180C (C.G.S) (0.27)Thermal Expansion - 28x106

Linear per 0C

Alloy Composition

Impurities

Electrical conductivity%age IACS 26at 200C

(lb/in3) (0.24)Tensile Strength N/mm2 283-241at 200C (lbf/in2) (41,000)Elongation at 200C %in 2in 10-16%Impact strength at at 200C J 56.9(unnotched samples) (ft.obf) (42)Hardness BHN 82-87

The ZL 7 is a derivative of the commonlyused and very successful ZL 3 alloy. ZL 7possesses similar properties to thenumber 3 alloy while minor changes tothe chemistry of this material haveenhanced its castability. The revisionshave allowed castings section of 0.6-0.7mm to be achieved using the hotchamber pressure die casting process.ZL 7 is not covered by the current EN1774 or 12844 zinc alloy standards.Application

This alloy should be selected for high volumecasting applications where thin sections arerequired to reduce weight/create space, finish isimportant and the retention of torsional rigidityassociated with metal structures and enclosuresis imperative. Like all zinc alloys ZL 7 offers theadded benefit of good EMI/RFI shieldingproperties and long term dimensional stabilitycombined with net shape manufacturing.

Typical applications include electronics,computer hardware, telecommunication devices,automotive and builders’ hardware etc.

Designers should be aware that the properties ofthis alloy change with age and reference shouldbe made to the aged properties at the designstage.

Copper - 0.013%Iron - 0.005%Lead - 0.003%Cadmium - 0.002%Tin - 0.001%Silicon - 0.01%

Tensile Strength MPa 283at 200CElongation - 10.0%(51 mm)Compressive Yield MPa 418strength 0.5%Hardness BHN 82Poisons ratio 0.27Impact Strength Joules 58Fatigue strength MPa 47

Alloy Composition

Impurities

Typical as cast physical and mechanical propertiesFreezing range 0C 381-387Density grams/cm3 6.6Coefficient of µ m/mK 27thermal expansionThermal conductivity W/m/hr/m2/0C 105

@ 70-1400CElectrical conductivity %IACS 26.9Electrical Resistivity µm ohm cm 6.4(unnotched samples) @ 200C

ZL5 is a zinc base pressure die castingalloy which conforms to EN 1774 1997Ingot Specification and is one of a familyof versatile high grade zinc alloysmanufactured by Brock Metal.Application

ZL5 is generally used for castings produced on ahot chamber pressure die casting machinewhere a slightly stronger and harder alloy thanZL3 is required and dimensional stability in theas cast condition is not such an importantcriterion. ZL5 has slightly better castability thanZL3 and therefore tends to be used for smallintricate castings or when surface preparation ofa ZL3 casting is difficult, prior to electroplating.Due to its higher Copper content the alloy ismore expensive than ZL3 therefore it’sapplication should be restricted to it’s correctuse.

ZL5 is easily machined, buffed, polished,lacquered and electroplated for decorative orfunctional purposes

The composition of ZL5 conforms to the currentEN 1774 Standard, which is now common to allEU countries.

(in/in) (0.006)Thermal Conductivity W/m0C 108.9at 180C (C.G.S) (0.26)Thermal Expansion - 28x106

Linear per 0C

Alloy Composition

Impurities

Typical as cast physical and mechanical propertiesElectrical conductivity

%age IACS 26at 200CSpecific Gravity - 6.7Density Kg/m3 6,700

(lb/in3) (0.24)Tensile Strength N/mm2 328-270at 200C (lbf/in2) (47,000)Elongation at 200C %in 2in 7-13Impact strength at at 200C J 54-65(unnotched samples) (ft.obf) (43)Hardness BHN 92-80

The ZL 7 is a derivative of the commonlyused and very successful ZL 3 alloy. ZL 7possesses similar properties to thenumber 3 alloy while minor changes tothe chemistry of this material haveenhanced its castability. The revisionshave allowed castings section of 0.6-0.7mm to be achieved using the hotchamber pressure die casting process.ZL 7 is not covered by the current EN1774 or 12844 zinc alloy standards.Application

This alloy should be selected for high volumecasting applications where thin sections arerequired to reduce weight/create space, finish isimportant and the retention of torsional rigidityassociated with metal structures and enclosuresis imperative. Like all zinc alloys ZL 7 offers theadded benefit of good EMI/RFI shieldingproperties and long term dimensional stabilitycombined with net shape manufacturing.

Typical applications include electronics,computer hardware, telecommunication devices,automotive and builders’ hardware etc.

Designers should be aware that the properties ofthis alloy change with age and reference shouldbe made to the aged properties at the designstage.

Copper - 0.013%Iron - 0.005%Lead - 0.003%Cadmium - 0.002%Tin - 0.001%Silicon - 0.01%

Tensile Strength MPa 283at 200CElongation - 10.0%(51 mm)Compressive Yield MPa 418strength 0.5%Hardness BHN 82Poisons ratio 0.27Impact Strength Joules 58Fatigue strength MPa 47

Alloy Composition

Impurities

Typical as cast physical and mechanical propertiesFreezing range 0C 381-387Density grams/cm3 6.6Coefficient of µ m/mK 27thermal expansionThermal conductivity W/m/hr/m2/0C 105

@ 70-1400CElectrical conductivity %IACS 26.9Electrical Resistivity µm ohm cm 6.4(unnotched samples) @ 200C

ZL5 is a zinc base pressure die castingalloy which conforms to EN 1774 1997Ingot Specification and is one of a familyof versatile high grade zinc alloysmanufactured by Brock Metal.Application

ZL5 is generally used for castings produced on ahot chamber pressure die casting machinewhere a slightly stronger and harder alloy thanZL3 is required and dimensional stability in theas cast condition is not such an importantcriterion. ZL5 has slightly better castability thanZL3 and therefore tends to be used for smallintricate castings or when surface preparation ofa ZL3 casting is difficult, prior to electroplating.Due to its higher Copper content the alloy ismore expensive than ZL3 therefore it’sapplication should be restricted to it’s correctuse.

ZL5 is easily machined, buffed, polished,lacquered and electroplated for decorative orfunctional purposes

The composition of ZL5 conforms to the currentEN 1774 Standard, which is now common to allEU countries.

(in/in) (0.006)Thermal Conductivity W/m0C 108.9at 180C (C.G.S) (0.26)Thermal Expansion - 28x106

Linear per 0C

Alloy Composition

Impurities

Typical as cast physical and mechanical propertiesElectrical conductivity

%age IACS 26at 200CSpecific Gravity - 6.7Density Kg/m3 6,700

(lb/in3) (0.24)Tensile Strength N/mm2 328-270at 200C (lbf/in2) (47,000)Elongation at 200C %in 2in 7-13Impact strength at at 200C J 54-65(unnotched samples) (ft.obf) (43)Hardness BHN 92-80

ZL-8ZL8 conforms to EN 1774 1997 IngotSpecification and is a hot chamberpressure die casting alloy which wasdeveloped to meet specific applicationsand is one of the family of versatile highgrade alloys manufactured by BrockMetal. ZL8 is a direct replacement for ZA8and can also be used to make sand andpermanent mould castings.ApplicationZL8 is designed to extend the application range ofZinc alloy diecastings. In the past Zinc alloys wereconsidered unsuitable for applications wheremoderate stress was anticipated at elevatedtemperatures. ZL8 offers the best creep resistanceof all hot chamber diecasting alloys and it shouldbe specified for structural or stressed applicationsfor which other Zinc alloys would be unsuitable.

Although it is the strongest of the hot chamberalloys, it still possesses all of the propertiesassociated with Zinc diecasting alloys. Thecombination of high strength, excellent dimensionalstability, good surface finish and definition make itideal for visible stressed parts which are subject toelevated temperature during service.

The increased levels of Aluminium have nosignificant effects on the finishing of castings madefrom this alloy. Finishes suitable for traditional Zincpressure die casting alloys can be applied to

castings made from ZL8 alloys with excellentresults.

Typical applications for this alloy are under bonnetautomotive parts, stressed parts for hazardous ormining environments, stressed electrical orcomputer parts, micro wave guides etc.

This specification has been taken from EN 1774 –Zinc and Zinc Alloys – Alloys for Foundry Purposes– Ingot and Liquid.

The Noranda Research Centre, Quebec, Canada,developed the ZL8 alloy and carried out thedetailed characterization of the material propertiespertaining to this alloy.

- (0.104)Solidification Cm/m 1.10Shrinkage (in/ft) (0.132)Casting Shrinkage mm/mm 0.007

(in/in) (0.007)Thermal Conductivity W/m0C 114.7at 180C BTU/Ft/hr/Ft2/F0 66.3Thermal Expansion - 23.3x106

Linear per 0C

Alloy Composition

Impurities

Electrical conductivity%age IACS 27.7at 200C

(lb/in3) (0.227)Tensile Strength N/mm2 374at 200C (lbf/in2) (54,200)Elongation at 200C %in 2in 6-10Impact strength at at 200C J 42(unnotched samples) (ft.obf) (31)Hardness BHN 103

PRESSURE DIE CASTING FOUNDRY ALLOY

ZL-12ZL12 is a 12% Aluminium – Zinc alloywhich conforms to EN 1774 1997. It hasbeen developed for use as a general-purpose foundry alloy. Its uniqueproperties enable it to be cast using anyof the conventional gravity castingprocesses. ZL12 is a strong, sound alloycapable of casting thin sections andintricate details. The economical ZL12has low initial and conversions costs. Itcan be cold chamber pressure die castusing a similar process to that used formaking Aluminium pressure castings.

Mechanical Sand Cast PermanentMould(Gravity Die)

Tensile N/mm2 276-310 345-380(lbf/in2x103) (40-45) (50-55)

Elongation % in 2 in 3-4 4-7Impact Strength J 5.4-10.8 17.6(unnotchedsamples) (ft.lbf) (4-8) (13)Hardness BHN 105-125

Mechanical

The casting properties of ZL12 enable it tocompete favourably with other cast metals suchas Iron, Brass, Bronze and Aluminium Alloys.ZL12 has excellent machining characteristics,good corrosion resistance and requires only theminimum of surface preparation for easyelectroplating or painting. The originalspecification for this alloy was developed by theInternational Lead Zinc Research OrganisationInc. New York USA. ZL12 was known as Kayem12 and ZA12 in the past. ZL12 is the EN 1774equivalent of these alloys.

Advantages• Economical alloy costwith clean low-cost melting& low metal loss• Insensitive to differentcooling rates allowing it tobe cast by all gravitycasting processes• Excellent castability givingpressure tightness, thinsections, intricate detail.• Low shrinkage & gasporosity, high sandreclamation.• Existing patternequipment and gravity diescan be used• Excellent machiningproperties• Excellent buffing andpolishing characteristics• Easily electroplated,painted or lacquered.• Good corrosion resistance• Excellent tensile strengthand hardness at ambienttemperatures• Non-sparking alloysuitable for hazardousenvironments• Good bearing and wearproperties for lightly loadedapplications

Density g/cm3 603(lb/in3) (0.218)

Pattern Makers cm/m 1.30 1.04Shrinkage (in/ft) (3/32) (1/8)ElectricalConductivity %age IACS 25

Physical

Melting Range 0C 380-430CastingTemperature 0C 475-520Thermal Conductivityat 24 0C W/m0C 0.21-0 22

Thermal

ZL12 BrassBS Aluminium GreyCast1400SCB3 AlloyLM6 Iron

Tensile Strength N/mm2 276-380 185-250 160-185 165-345Elongation % 3-7 15-30 5-7 <0.5Hardness BHN 105-125 45-65 55-60 200-250Density g/cm3 6.03 8.5 2.65 7-7.5MeltingRange 0C 380-430 920-1000 580-640 1090-1260Thermal Conductivity W/m0C 0.21 0.26 0.34 0.1-0.12Electrical Conductivity %age 25 25 37 -

IACSMachinability Rating VeryGood VeryGood Fair FairFinishingCharacteristics VeryGood VeryGood Fair Poor

Comparison of Typical Properties

Properties vary for different processes. Further data available in the technical resource area on brockmetal.com

ZL-8ZL8 conforms to EN 1774 1997 IngotSpecification and is a hot chamberpressure die casting alloy which wasdeveloped to meet specific applicationsand is one of the family of versatile highgrade alloys manufactured by BrockMetal. ZL8 is a direct replacement for ZA8and can also be used to make sand andpermanent mould castings.ApplicationZL8 is designed to extend the application range ofZinc alloy diecastings. In the past Zinc alloys wereconsidered unsuitable for applications wheremoderate stress was anticipated at elevatedtemperatures. ZL8 offers the best creep resistanceof all hot chamber diecasting alloys and it shouldbe specified for structural or stressed applicationsfor which other Zinc alloys would be unsuitable.

Although it is the strongest of the hot chamberalloys, it still possesses all of the propertiesassociated with Zinc diecasting alloys. Thecombination of high strength, excellent dimensionalstability, good surface finish and definition make itideal for visible stressed parts which are subject toelevated temperature during service.

The increased levels of Aluminium have nosignificant effects on the finishing of castings madefrom this alloy. Finishes suitable for traditional Zincpressure die casting alloys can be applied to

castings made from ZL8 alloys with excellentresults.

Typical applications for this alloy are under bonnetautomotive parts, stressed parts for hazardous ormining environments, stressed electrical orcomputer parts, micro wave guides etc.

This specification has been taken from EN 1774 –Zinc and Zinc Alloys – Alloys for Foundry Purposes– Ingot and Liquid.

The Noranda Research Centre, Quebec, Canada,developed the ZL8 alloy and carried out thedetailed characterization of the material propertiespertaining to this alloy.

- (0.104)Solidification Cm/m 1.10Shrinkage (in/ft) (0.132)Casting Shrinkage mm/mm 0.007

(in/in) (0.007)Thermal Conductivity W/m0C 114.7at 180C BTU/Ft/hr/Ft2/F0 66.3Thermal Expansion - 23.3x106

Linear per 0C

Alloy Composition

Impurities

Electrical conductivity%age IACS 27.7at 200C

(lb/in3) (0.227)Tensile Strength N/mm2 374at 200C (lbf/in2) (54,200)Elongation at 200C %in 2in 6-10Impact strength at at 200C J 42(unnotched samples) (ft.obf) (31)Hardness BHN 103

PRESSURE DIE CASTING FOUNDRY ALLOY

ZL-12ZL12 is a 12% Aluminium – Zinc alloywhich conforms to EN 1774 1997. It hasbeen developed for use as a general-purpose foundry alloy. Its uniqueproperties enable it to be cast using anyof the conventional gravity castingprocesses. ZL12 is a strong, sound alloycapable of casting thin sections andintricate details. The economical ZL12has low initial and conversions costs. Itcan be cold chamber pressure die castusing a similar process to that used formaking Aluminium pressure castings.

Mechanical Sand Cast PermanentMould(Gravity Die)

Tensile N/mm2 276-310 345-380(lbf/in2x103) (40-45) (50-55)

Elongation % in 2 in 3-4 4-7Impact Strength J 5.4-10.8 17.6(unnotchedsamples) (ft.lbf) (4-8) (13)Hardness BHN 105-125

Mechanical

The casting properties of ZL12 enable it tocompete favourably with other cast metals suchas Iron, Brass, Bronze and Aluminium Alloys.ZL12 has excellent machining characteristics,good corrosion resistance and requires only theminimum of surface preparation for easyelectroplating or painting. The originalspecification for this alloy was developed by theInternational Lead Zinc Research OrganisationInc. New York USA. ZL12 was known as Kayem12 and ZA12 in the past. ZL12 is the EN 1774equivalent of these alloys.

Advantages• Economical alloy costwith clean low-cost melting& low metal loss• Insensitive to differentcooling rates allowing it tobe cast by all gravitycasting processes• Excellent castability givingpressure tightness, thinsections, intricate detail.• Low shrinkage & gasporosity, high sandreclamation.• Existing patternequipment and gravity diescan be used• Excellent machiningproperties• Excellent buffing andpolishing characteristics• Easily electroplated,painted or lacquered.• Good corrosion resistance• Excellent tensile strengthand hardness at ambienttemperatures• Non-sparking alloysuitable for hazardousenvironments• Good bearing and wearproperties for lightly loadedapplications

Density g/cm3 603(lb/in3) (0.218)

Pattern Makers cm/m 1.30 1.04Shrinkage (in/ft) (3/32) (1/8)ElectricalConductivity %age IACS 25

Physical

Melting Range 0C 380-430CastingTemperature 0C 475-520Thermal Conductivityat 24 0C W/m0C 0.21-0 22

Thermal

Tensile Strength N/mm2 276-380 185-250 160-185 165-345Elongation % 3-7 15-30 5-7 <0.5Hardness BHN 105-125 45-65 55-60 200-250Density g/cm3 6.03 8.5 2.65 7-7.5MeltingRange 0C 380-430 920-1000 580-640 1090-1260Thermal Conductivity W/m0C 0.21 0.26 0.34 0.1-0.12Electrical Conductivity %age 25 25 37 -

IACSMachinability Rating VeryGood VeryGood Fair FairFinishingCharacteristics VeryGood VeryGood Fair Poor

FOUNDRY ALLOY

ZL-27ZL27 is a 27% Aluminium – Zinc alloywhich conforms to EN 1774 1997. It hasbeen developed to address the need foran exceptionably high strength goodbearing property Zinc base casting alloy.To improve the as cast ductility ZL27 canbe given an inexpensive heat treatment.As with other Zinc Alloys, ZL27 is a soundalloy capable of casting thin sections &intricate detail. However, due to ZL27casting characteristics large castings arebest produced by sand moulding andthin-sectioned smaller castings can beproduced either by permanent or shellmoulding.

ZL27 can be pressure diecast on a cold chambermachine. ZL27 has excellent machiningcharacteristics and good corrosion resistance.The economical cost of ZL27 together with lowconversion costs and excellent properties enableit to compete favourably with other cast metalssuch as malleable and grey Iron, Manganese andAluminium Bronzes and high strength Aluminiumalloys.

The Noranda Research Centre, Quebec, Canada,developed the ZA 27 alloy and carried out thedetailed characterization of the materialproperties pertaining to this alloy.

Mechanical Sand Cast Heat treatedTensile N/mm2 400-440 310-324

(lbf/in2x103) (58-64) (45-47)Elongation % in 2 in 3-6 8-11Impact Strength J 14.9 25.7(unnotchedsamples) (ft.lbf) (11) (19)Hardness BHN 110-120 90-100

Mechanical

Density g/cm3 5.01(lb/in3) (.181)

Pattern Makers cm/m 1.30Shrinkage (in/ft) (5/32)ElectricalConductivity %age IACS 28

Physical

Melting Range 0C 380-490CastingTemperature 0C 510-560

Thermal

Tensile Strength N/mm2 310-440 185-250 160-185 165-345Elongation % 3-11 15-30 5-7 <0.5Hardness BHN 90-120 45-65 55-60 200-250Density g/cm3 5.01 8.5 2.65 7-7.5MeltingRange 0C 380-490 920-1000 580-640 1090-1260Electrical Conductivity %age 28 25 37 -

IACSMachinability Rating VeryGood VeryGood Fair Fair

Advantages• Approximately 43%lighter than Bronze and30% lighter than cast Iron• Economical alloy costwith clean low-costmelting and low metalloss• Easily cast by sandmoulding, shell moulding,permanent moulding andcold chamber machinepressure die.• Good castability givingpressure tightness, thinsections, and good ascast finish.• Low shrinkage and gasporosity, high sandreclamation.• Excellent machiningproperties• Good corrosionresistance• Excellent tensilestrength and hardness atambient temperatures• Inexpensive heattreatment to improveductility.• Excellent bearing andwear• Good creep propertiesProperties vary for different processes. Further data available in the technical resource area on brockmetal.com

COLD CHAMBER PRESSURE DIE CASTING ALLOY

ILZRO 16

Thermal expansionmm/mm/0C 27@10 -1000C

Specific heat capacityJ/kg/0C 402@ 20-1000C

Thermal conductivityW/m/hr/m2/0C 109@70-1400C

Electrical resistivityµohm-cm 8.4@ 200C

ILZRO 16 is a specialized zinc alloy whichconforms to the EN 1774 1997 Ingotspecification and is one of a family of highgrade zinc alloys manufactured by theBrock Metal Company Limited. Castingsmade from this alloy should conform toEN 12844 Zinc alloy castingsspecifications.ApplicationIlzro 16 was developed to address a specificapplication range within the zinc alloy range. Ithas a very explicit design application envelopewhich other alloys within the range are unable toaddress. The chemistry of this alloy dictates themanufacturing methods that can be adopted andeffectively rule out the use of the most efficienthot chamber pressure die-casting process.

These factors have limited the potentialapplications for this alloy and it’s use in themarket place has been limited. However, ZL16does have exceptional creep properties for a zincalloy and retains the design benefits anddimensional capabilities offered by the moretraditional hot chamber alloys. Use of this alloyshould be considered where moderate stress, atelevated temperatures are anticipated andparticularly when this is combined with a need forhigh complexity and dimensional accuracy.

Detailed creep data and fracture toughness

figures are covered in the technical resource fileon the Brock Metal web site. Brock would advisethat the potential user of this alloy considers thedesign of the part in line with good designpractice and the properties of this alloy. It wouldbe advisable to consult with the die cast supplierto ensure that they are prepared to manufacturecastings from this alloy prior to committing thefinal design solution. This consultation would alsoensure that process capability and cost effectivetool design is achieved.

Tensile strengthMPa 230at 200C

Proof StressMPa 142(0.2% offset)

Elongation (51 mm) 5.5%Hardness 500 kg BHN 76Density g/cm3 7.1Solidification range 0C 418-416W/m/hr/m2/0C

Min MaxAluminium 0.01% 0.04%Copper 1.0% 1.5%Chromium 0.1% 0.2%Titanium 0.15% 0.25%Zinc Remainder

Min MaxMagnesium - 0.02%Lead - 0.005%Cadmium - 0.004%Tin - 0.003%Iron - 0.04%Silicon - 0.04%

Alloy Composition

Impurities

FOUNDRY ALLOY

ZL-27ZL27 is a 27% Aluminium – Zinc alloywhich conforms to EN 1774 1997. It hasbeen developed to address the need foran exceptionably high strength goodbearing property Zinc base casting alloy.To improve the as cast ductility ZL27 canbe given an inexpensive heat treatment.As with other Zinc Alloys, ZL27 is a soundalloy capable of casting thin sections &intricate detail. However, due to ZL27casting characteristics large castings arebest produced by sand moulding andthin-sectioned smaller castings can beproduced either by permanent or shellmoulding.

ZL27 can be pressure diecast on a cold chambermachine. ZL27 has excellent machiningcharacteristics and good corrosion resistance.The economical cost of ZL27 together with lowconversion costs and excellent properties enableit to compete favourably with other cast metalssuch as malleable and grey Iron, Manganese andAluminium Bronzes and high strength Aluminiumalloys.

The Noranda Research Centre, Quebec, Canada,developed the ZA 27 alloy and carried out thedetailed characterization of the materialproperties pertaining to this alloy.

Mechanical Sand Cast Heat treatedTensile N/mm2 400-440 310-324

(lbf/in2x103) (58-64) (45-47)Elongation % in 2 in 3-6 8-11Impact Strength J 14.9 25.7(unnotchedsamples) (ft.lbf) (11) (19)Hardness BHN 110-120 90-100

Mechanical

Density g/cm3 5.01(lb/in3) (.181)

Pattern Makers cm/m 1.30Shrinkage (in/ft) (5/32)ElectricalConductivity %age IACS 28

Physical

Melting Range 0C 380-490CastingTemperature 0C 510-560

Thermal

Tensile Strength N/mm2 310-440 185-250 160-185 165-345Elongation % 3-11 15-30 5-7 <0.5Hardness BHN 90-120 45-65 55-60 200-250Density g/cm3 5.01 8.5 2.65 7-7.5MeltingRange 0C 380-490 920-1000 580-640 1090-1260Electrical Conductivity %age 28 25 37 -

IACSMachinability Rating VeryGood VeryGood Fair Fair

Advantages• Approximately 43%lighter than Bronze and30% lighter than cast Iron• Economical alloy costwith clean low-costmelting and low metalloss• Easily cast by sandmoulding, shell moulding,permanent moulding andcold chamber machinepressure die.• Good castability givingpressure tightness, thinsections, and good ascast finish.• Low shrinkage and gasporosity, high sandreclamation.• Excellent machiningproperties• Good corrosionresistance• Excellent tensilestrength and hardness atambient temperatures• Inexpensive heattreatment to improveductility.• Excellent bearing andwear• Good creep propertiesProperties vary for different processes. Further data available in the technical resource area on brockmetal.com

COLD CHAMBER PRESSURE DIE CASTING ALLOY

ILZRO 16

Thermal expansionmm/mm/0C 27@10 -1000C

Specific heat capacityJ/kg/0C 402@ 20-1000C

Thermal conductivityW/m/hr/m2/0C 109@70-1400C

Electrical resistivityµohm-cm 8.4@ 200C

ILZRO 16 is a specialized zinc alloy whichconforms to the EN 1774 1997 Ingotspecification and is one of a family of highgrade zinc alloys manufactured by theBrock Metal Company Limited. Castingsmade from this alloy should conform toEN 12844 Zinc alloy castingsspecifications.ApplicationIlzro 16 was developed to address a specificapplication range within the zinc alloy range. Ithas a very explicit design application envelopewhich other alloys within the range are unable toaddress. The chemistry of this alloy dictates themanufacturing methods that can be adopted andeffectively rule out the use of the most efficienthot chamber pressure die-casting process.

These factors have limited the potentialapplications for this alloy and it’s use in themarket place has been limited. However, ZL16does have exceptional creep properties for a zincalloy and retains the design benefits anddimensional capabilities offered by the moretraditional hot chamber alloys. Use of this alloyshould be considered where moderate stress, atelevated temperatures are anticipated andparticularly when this is combined with a need forhigh complexity and dimensional accuracy.

Detailed creep data and fracture toughness

figures are covered in the technical resource fileon the Brock Metal web site. Brock would advisethat the potential user of this alloy considers thedesign of the part in line with good designpractice and the properties of this alloy. It wouldbe advisable to consult with the die cast supplierto ensure that they are prepared to manufacturecastings from this alloy prior to committing thefinal design solution. This consultation would alsoensure that process capability and cost effectivetool design is achieved.

Tensile strengthMPa 230at 200C

Proof StressMPa 142(0.2% offset)

Elongation (51 mm) 5.5%Hardness 500 kg BHN 76Density g/cm3 7.1Solidification range 0C 418-416W/m/hr/m2/0C

Min MaxAluminium 0.01% 0.04%Copper 1.0% 1.5%Chromium 0.1% 0.2%Titanium 0.15% 0.25%Zinc Remainder

Min MaxMagnesium - 0.02%Lead - 0.005%Cadmium - 0.004%Tin - 0.003%Iron - 0.04%Silicon - 0.04%

Alloy Composition

Impurities

EXAMPLES OF WIDE RANGE SPECIALIST ALLOYS AVAILABLE

SPECIAL ALLOYS

ACuZincTM5

AcuZincTM 5 is a special die-casting alloy,developed by General Motors to satisfythe demands of specific automotiveapplications. Subsequent testsdemonstrated that this alloy had a muchbroader application range than originallyanticipated and GM granted licences toselected Zinc alloy producers to allow themto manufacture this alloy.The Brock Metal Company Limited is alicensed manufacturer of the ACuZinc alloyrange. As such Brock are able to advise onthe use of the alloy and its specialproperties. This alloy is not covered by thecurrent EN specification but is covered byASTM and other US standards.Application

The ACuZincTM 5 alloy was developed to extendthe operating range of the traditional hot chamberZinc die-casting alloys and to rival the performanceof the cold chamber alloys while retaining the costeffective manufacturing benefits of the hotchamber die-casting process. A prime target foruse of this alloy was the replacement of sinteredmetal parts on a performance basis with a morecost effective zinc alloy based solutions.

The high Copper content present in this alloyincreases the general strength of the material, whileimproving both hardness and rigidity. Thisperformance increase is apparent at higheroperating/service temperatures and whereincreased wear and impingement resistance is anecessity. There is a marked cost penaltyassociated with the use of this alloy and thereforeuse of ACuZinc should be confined to applicationswhere the increased properties are essential andcan be justified on a commercial basis.

Min MaxCopper 5.0% 6.0%Aluminium 2.8% 3.3%Magnesium 0.025% 0.05%Zinc Balance

Iron - 0.075%Lead - 0.005%Cadmium - 0.004%Ti - 0.003%

Tensile Strength MPa 407at 200CYield strength 0.2% MPa 338Elongation - 6.0%(51 mm)Young’s Modulus MPa 100x103

Compressive Yield MPa 418strength 0.5%Hardness BHN 105-125Creep Rate 1500C s-1x106 0.5

@3.7 ksiPoisons ratio 0.29

Alloy Composition

Impurities

Typical as cast physical and mechanical propertiesImpact Strength Joules 16Fatigue strength MPa 84Hardness BHN 105Melting range 0C 460-480Density grams/cm3 6.85Coefficient of µ m/mK 24.1thermal expansionThermal conductivity j/s/cm/K 1.06Electrical conductivity %IACS 26.9Electrical Resistivity µm ohm cm 6.4

Military Sacrificial Anode Specification

Chemical Analysis:Alloying Additions ImpuritiesAl 0.10 - 0.50 Cu 0.005Cd 0.025 - 0.07 Fe 0.005

Pb 0.006Others 0.10

MILITARY - 18001

Chemical Analysis:Alloying Additions Impurities

Aluminium 3.5 - 3.7% Iron 0.020% maxCopper 1.1 - 1.3% Lead 0.003% max

Magnesium 0.4% Cadmium 0.003% maxZinc Balance Tin 0.001% max

SPINCAST ALLOY 1

SPINCAST ALLOY 2

Aluminium 0.05 - 0.055% Copper 0.010% maxMagnesium 0.4 - 0.45% Iron 0.0010% max

Zinc Balance Lead 0.003% maxCadmium 0.0010%

Tin 0.0010%

ZAMI ALLOY

EXAMPLES OF WIDE RANGE SPECIALIST ALLOYS AVAILABLE

SPECIAL ALLOYS

ACuZincTM5

AcuZincTM 5 is a special die-casting alloy,developed by General Motors to satisfythe demands of specific automotiveapplications. Subsequent testsdemonstrated that this alloy had a muchbroader application range than originallyanticipated and GM granted licences toselected Zinc alloy producers to allow themto manufacture this alloy.The Brock Metal Company Limited is alicensed manufacturer of the ACuZinc alloyrange. As such Brock are able to advise onthe use of the alloy and its specialproperties. This alloy is not covered by thecurrent EN specification but is covered byASTM and other US standards.Application

The ACuZincTM 5 alloy was developed to extendthe operating range of the traditional hot chamberZinc die-casting alloys and to rival the performanceof the cold chamber alloys while retaining the costeffective manufacturing benefits of the hotchamber die-casting process. A prime target foruse of this alloy was the replacement of sinteredmetal parts on a performance basis with a morecost effective zinc alloy based solutions.

The high Copper content present in this alloyincreases the general strength of the material, whileimproving both hardness and rigidity. Thisperformance increase is apparent at higheroperating/service temperatures and whereincreased wear and impingement resistance is anecessity. There is a marked cost penaltyassociated with the use of this alloy and thereforeuse of ACuZinc should be confined to applicationswhere the increased properties are essential andcan be justified on a commercial basis.

Min MaxCopper 5.0% 6.0%Aluminium 2.8% 3.3%Magnesium 0.025% 0.05%Zinc Balance

Iron - 0.075%Lead - 0.005%Cadmium - 0.004%Ti - 0.003%

Tensile Strength MPa 407at 200CYield strength 0.2% MPa 338Elongation - 6.0%(51 mm)Young’s Modulus MPa 100x103

Compressive Yield MPa 418strength 0.5%Hardness BHN 105-125Creep Rate 1500C s-1x106 0.5

@3.7 ksiPoisons ratio 0.29

Alloy Composition

Impurities

Typical as cast physical and mechanical propertiesImpact Strength Joules 16Fatigue strength MPa 84Hardness BHN 105Melting range 0C 460-480Density grams/cm3 6.85Coefficient of µ m/mK 24.1thermal expansionThermal conductivity j/s/cm/K 1.06Electrical conductivity %IACS 26.9Electrical Resistivity µm ohm cm 6.4

Military Sacrificial Anode Specification

Chemical Analysis:Alloying Additions ImpuritiesAl 0.10 - 0.50 Cu 0.005Cd 0.025 - 0.07 Fe 0.005

Pb 0.006Others 0.10

MILITARY - 18001

SPINCAST ALLOY 1

SPINCAST ALLOY 2

Aluminium 0.05 - 0.055% Copper 0.010% maxMagnesium 0.4 - 0.45% Iron 0.0010% max

Zinc Balance Lead 0.003% maxCadmium 0.0010%

Tin 0.0010%

ZAMI ALLOY

The Brock Metal Company Ltd

Walsall road, norton canes, cannock, Staffordshire. WS11 9nr

United Kingdom

tel: +44 (0) 1543 276666 fax: +44(0) 1543 246418

email: [email protected]

www.brockmetal.com

diecasting zinc alloy specifications - english

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