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zamak

{{Short description|Metal alloy}}

File:Zamak.jpg

ZAMAK (or Zamac, formerly trademarked as MAZAK{{Citation| title = Zamak Latest Status Info| url = http://tarr.uspto.gov/servlet/tarr?regser=serial&entry=71234673| access-date = 2008-03-02}}) 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.

The name zamak is an acronym of the German names for the metals of which the alloys are composed: {{lang|de|Zink}} (zinc), {{lang|de|Aluminium}}, {{lang|de|Magnesium}} and {{lang|de|Kupfer}} (copper). 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.{{Citation | title = Diecasting Alloys| url =http://www.eazall.com/diecastalloys.aspx| access-date = 2008-03-02}} These alloys are most commonly die cast. 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.{{Citation| last1 = Wanhill| first1 = R.J.H.| last2 = Hattenberg| first2 = T.| title = Corrosion-induced cracking of model train zinc-aluminum die castings| publisher = National Aerospace Laboratory NLR|date = May 2005| id = NLR-TP-2005-205 | url = http://www.nlr.nl/id~4210/lang~en.pdf| archive-date =2011-07-16 | archive-url = https://web.archive.org/web/20110716065232/http://www.nlr.nl/id~4210/lang~en.pdf | postscript = .}} 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.

Mazak

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.{{Citation |title=A History of the Zinc Smelting Industry in Britain |first1=E.J. |last1=Cocks |first2=B. |last2=Walters |publisher=Harrap |year=1968 |isbn=0-245-59377-2 | postscript=.}}

Standards

Zinc alloy chemical composition standards are defined per country by the standard listed below:

class="wikitable"

|+ Zinc alloy standards per country{{Citation| title =World wide zinc die casting standards| publisher =Nyrstar| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/ZincDieCastingStandardsWorldwide.htm| access-date =2008-02-25}}.

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:

class="wikitable"

|+ Various names for zamak alloys

Traditional name

! Short composition name

! Form

! Common

! ASTM†

! Short European designation

! JIS

! China

! UK BS 1004Now defunct due to standardization of European countries under EN 1774 & EN 12844.

! France NFA 55-010

! Germany DIN 1743-2

! UNS

! Other

rowspan=2| Zamak 2{{Citation|title=ASTM B86-04e2|date=2004-10-01|url=https://www.eazall.com/PublicDoc/ZincDie%20CastingPropertiesGuide2012.pdf|access-date=2008-02-10}}{{Citation|title=ASTM B240-98|date=1998-05-01|url=https://www.eazall.com/PublicDoc/ZincDie%20CastingPropertiesGuide2012.pdf|access-date=2008-02-10}}
or
Kirksite{{Cite book|last=Semiatin|first=S. L.|url=https://books.google.com/books?id=ekEe4UwqkVUC|title=ASM Handbook, Volume 14B: Metalworking: Sheet Forming|date=2006|publisher=ASM International|isbn=978-0-87170-710-9|language=en}}

| rowspan=2| ZnAl4Cu3

| Ingot

| rowspan=2| Alloy 2

| style="background:green;color:white;" rowspan=2| AC 43A

| ZL0430{{Citation| title = Alloy designation - cross reference table | url = http://www.brockmetal.com/downloads/documents/NOGUOHRYMM_designation_and_stress_curves.pdf | access-date = 2010-10-31 | archive-url = https://web.archive.org/web/20110708094953/http://www.brockmetal.com/downloads/documents/NOGUOHRYMM_designation_and_stress_curves.pdf | url-status = usurped | archive-date = 2011-07-08}}

| rowspan=2| -

| ZX04

| rowspan=2| -

| rowspan=2| Z-A4U3

| rowspan=2| Z430

| Z35540

| ZL2, ZA-2, ZN-002

Cast

| ZP0430

| -

| Z35541

| ZP2, ZA-2, ZN-002

rowspan=2| Zamak 3

| rowspan=2| ZnAl4

| Ingot

| rowspan=2| Alloy 3

| style="background:white" rowspan=2| AG 40A

| ZL0400

| Ingot type 2{{Citation| title = JIS H2201 - Japanese Industrial Standard - Zinc alloy ingot for die casting (1999)| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/JIS_H2201-Zinc-Alloy-Ingot-for-die-casting.htm | access-date =2008-02-26}}

| ZX01

| rowspan=2| Alloy A

| rowspan=2| Z-A4

| rowspan=2| Z400

| Z35521

| ZL3, ZA-3, ZN-003

Cast

| ZP0400

| ZDC2{{Citation| title = JIS H5301 - Japanese Industrial Standard - Zinc alloy die casting (1979)| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/JIS_H5301-Zinc-Alloy-die-castings.htm | access-date =2008-02-26}}

| -

| Z33520

| ZP3, ZA-3, ZN-003

Zamak 4{{Citation| title = zamak 4 (Alloy 4)| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/Zinc-Diecasting-Product-Zamak4-GZ4/Zamak4-GZ4-ZincAlloyForHotChamberDieCasting.htm

| access-date = 2008-03-01}}

|

| Ingot

| colspan=9| Used in Asia only

| ZA-4, ZN-004

rowspan=2| Zamak 5

| rowspan=2| ZnAl4Cu1

| Ingot

| rowspan=2| Alloy 5

| style="background:black; color:white" rowspan=2| AC 41A

| ZL0410

| Ingot type 1

| ZX03

| rowspan=2| Alloy B

| rowspan=2| Z-A4UI

| rowspan=2| Z410

| Z35530

| ZL5, ZA-5, ZN-005

Cast

| ZP0410

| ZDC1

| -

| Z35531

| ZP5, ZA-5, ZN-005

rowspan=2| Zamak 7

| rowspan=2| ZnAl4Ni

| Ingot

| rowspan=2| Alloy 7

| style="background:brown;color:white;" rowspan=2| AG 40B

| rowspan=2| -

| rowspan=2| -

| ZX02

| rowspan=2| -

| rowspan=2| -

| rowspan=2| -

| Z33522

| rowspan=2|ZA-7, ZN-007

Cast

| -

| Z33523

colspan=12 | †color of the cell is the color of the material designated by ASTM B908.

The short European designation code breaks down as follows (using ZL0430 as the example):

  • 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==

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.

Zamak 2 is also known as Kirksite when gravity cast for use as a die.{{Citation| title = Husite Engineering - Benefits of Cast Kirksite Tooling| url = http://husite.biz/kirksite.html| access-date = April 19, 2011| archive-date = March 1, 2022| archive-url = https://web.archive.org/web/20220301180438/https://husite.biz/kirksite.html| url-status = usurped}} It was originally designed for low volume sheet metal dies.{{Citation| first1 = Paul J. | last1 = Armstrong | first2 = Bill | last2 = Petch | title = Cast Kirksite Re-Emerges as RT Approach for Molding Plastics| url = http://www.armstrongmold.com/pages/kirksitearticle.html|access-date=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}}. It later gained popularity for making short run injection molding dies. It is also less commonly used for non-sparking tools and mandrels for metal spinning.

class="wikitable"

|+ Zamak 2 composition per standard

! colspan=2|

! colspan=3|Alloying elements

! colspan=8|Impurities

Standard

! Limit

! Al

! Cu

! Mg

! Pb

! Cd

! Sn

! Fe

! Ni

! Si

! In

! Tl

rowspan=2|ASTM B240 (Ingot)

| min

| 3.9

| 2.6

| 0.025

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 2.9

| 0.05

| 0.004

| 0.003

| 0.002

| 0.075

| -

| -

| -

| -

rowspan=2|ASTM B86 (Cast)

| min

| 3.5

| 2.6

| 0.025

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 2.9

| 0.05

| 0.005

| 0.004

| 0.003

| 0.1

| -

| -

| -

| -

rowspan=2|EN1774 (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

| -

| -

rowspan=2|EN12844 (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

| -

| -

rowspan=2|GB8738-88

| min

| 3.9

| 2.6

| 0.03

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 3.1

| 0.06

| 0.004

| 0.003

| 0.0015

| 0.035

| -

| -

| -

| -

class="wikitable"

|+ Zamak 2 properties{{Citation| title = ZL2/ZL0430/ZnAl4Cu3 (Zamak 2)| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/Zinc-Diecasting-Product-ZL0430-ZL2-Zamak2-GZ2-EDZA2-Alloy2-Overcor2/ZL0430-ZL2-ZnAl4Cu3-ZP0430-ZP2-Zamak2-Zamak-2-Z430-ZincAlloyforhotchamberdiecasting.htm | access-date = 2008-02-29}}

Property

! Metric value

! Imperial value

colspan=3| 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

| colspan=2 align="center"| 3% (2% aged)

Elongation at fracture

| colspan=2 align="center"| 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

| colspan=2 align="center"| 130 Brinell (98 Brinell aged)

Modulus of elasticity

| 96 GPa

| 14,000,000 psi

colspan=3| 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

| colspan=2 align="center"| 0.08

=KS=

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.

class="wikitable"

|+ KS composition

! colspan=2|

! colspan=3|Alloying elements

! colspan=8|Impurities

Standard

! Limit

! Al

! Cu

! Mg

! Pb

! Cd

! Sn

! Fe

! Ni

! Si

! In

! Tl

rowspan=2|Nyrstar

| min

| 3.8

| 2.5

| 0.4

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.2

| 3.5

| 0.6

| 0.003

| 0.003

| 0.001

| 0.020

| -

| -

| -

| -

class="wikitable"

|+ KS properties{{Citation| title = KS (spin casting alloy)| url=http://www.nyrstar.com/nyrstar/en/products/zincdiecast/techdownloads/4520525 | access-date=2008-03-15}}

Property

! Metric value

! Imperial value

colspan=3| Mechanical properties
Ultimate tensile strength

| < 200 MPa

| < 29,000 psi

Yield strength (0.2% offset)

| < 200 MPa

| < 29,000 psi

Elongation

| colspan=2 align="center"| < 2%

Hardness

| colspan=2 align="center"| 150 Brinell max

colspan=3| 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

| colspan=2 align="center"| 25% IACS

Specific heat capacity

| 419 J/kg-°C

| 0.100 BTU/lb-°F

Coefficient of friction

| colspan=2 align="center"| 0.08

Zamak 3

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.

class="wikitable"

|+ Zamak 3 composition per standard

! colspan=2|

! colspan=3|Alloying elements

! colspan=8|Impurities

Standard

! Limit

! Al

! Cu†

! Mg

! Pb

! Cd

! Sn

! Fe

! Ni

! Si

! In

! Tl

rowspan=2|ASTM B240{{Citation| title = ASTM B240: Standard specification for zinc in ingot form for die casting: chemical composition| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/ASTMB240-zamak-and-zincdiecastingstandard-zincalloysUSA.htm

| access-date =2008-02-27}} (Ingot)

| min

| 3.9

| -

| 0.025

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 0.1

| 0.05

| 0.004

| 0.003

| 0.002

| 0.035

| -

| -

| -

| -

rowspan=2|ASTM B86{{Citation| title = ASTM B86: Standard specification for zinc die casting: chemical composition| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/ASTMB86-zamak-and-zincdiecastingstandard-zincalloysUSA.htm

| access-date =2008-02-27}} (Cast)

| min

| 3.5

| -

| 0.025

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 0.25

| 0.05

| 0.005

| 0.004

| 0.003

| 0.1

| -

| -

| -

| -

rowspan=2|EN1774{{Citation| title = EN1774 Standard - zinc and zinc alloys - alloys for foundry purposes - ingot and liquid| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/EN1774-zamak-and-zincdiecastingstandard-Alloys-for-foundry-purposes-ingot-and-liquid.htm

| access-date =2008-02-27}} (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

| -

| -

rowspan=2|EN12844{{Citation| title = EN12844: Standard - zinc and zinc alloys - castings - specification (September 1998)| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/EN12844-zamak-zincdiecastingstandard-zinc-and-zinc-alloys-castings-specifications.htm

| access-date =2008-02-27}} (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

| -

| -

rowspan=2|JIS H2201 (Ingot)

| min

| 3.9

| -

| 0.03

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 0.03

| 0.06

| 0.003

| 0.002

| 0.001

| 0.075

| -

| -

| -

| -

rowspan=2|JIS H5301 (Cast)

| min

| 3.5

| -

| 0.02

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 0.25

| 0.06

| 0.005

| 0.004

| 0.003

| 0.01

| -

| -

| -

| -

rowspan=2|AS1881{{Citation| title = AS1881 - Australia standard - Zinc alloys - casting ingots and casting requirements (1986)| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/AS1881-1986-Zinc-Alloys-Casting-ingots-and-castings-quaility-requirements.htm

| access-date =2008-02-27}}

| 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

rowspan=2|GB8738-88{{Citation| title = GB8738 - Chinese standard: zinc alloys ingots for casting (2006)| url =http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/ZZ_standards/DieCasting/GB8738-88-Zinc-Alloys-Casting-ingots-and-castings-quaility-requirements.htm

| access-date =2008-02-27}}

| min

| 3.9

| -

| 0.03

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 0.1

| 0.06

| 0.004

| 0.003

| 0.0015

| 0.035

| -

| -

| -

| -

colspan=13| †Impurity

class="wikitable"

|+ Zamak 3 properties{{Citation| title = ZL3/ZL0400/ZnAl4 (Zamak 3)| url = http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/Zinc-Diecasting-Product-ZL0400-ZL3-Zamak3-GZ3-EDZA3-Alloy5-OVERCOR3/ZL0400-ZL3-ZnAl4-ZP0400-ZP3-Zamak3-Zamak-3-Z400-ZincAlloyForHotChamberDieCasting.htm

| access-date = 2008-02-29}}

Property

! Metric value

! Imperial value

colspan=3| 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

| colspan=2 align="center"| 3%

Elongation at fracture

| colspan=2 align="center"| 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

| colspan=2 align="center"| 97 Brinell

Modulus of elasticity

| 96 GPa

| 14,000,000 psi

colspan=3| 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

| colspan=2 align="center"| 0.07

Zamak 4

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.{{Citation| title = zamak 4 (Alloy 4)| url=http://www.nyrstar.com/en/productsServices/products/zinc/ZincAlloysZamakProducts/Zinc-Diecasting-Product-Zamak4-GZ4/Zamak4-GZ4-ZincAlloyForHotChamberDieCasting.htm| access-date = 2008-03-09}}

class="wikitable"

|+ Zamak 4 composition per standard

! colspan=2|

! colspan=3|Alloying elements

! colspan=8|Impurities

Standard

! Limit

! Al

! Cu

! Mg

! Pb

! Cd

! Sn

! Fe

! Ni

! Si

! In

! Tl

rowspan=2|Ningbo Jinyi Alloy Material Co.{{Citation| title = ZN-004| url = http://www.jinyialloy.com/en/productsmore.asp?id=8| access-date = 2008-03-01| archive-date = 2012-02-10| archive-url = https://web.archive.org/web/20120210184957/http://www.jinyialloy.com/en/productsmore.asp?id=8| url-status = dead}}

| min

| 3.9

| 0.3

| 0.03

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 0.5

| 0.06

| 0.003

| 0.002

| 0.002

| 0.075

| -

| -

| -

| -

class="wikitable"

|+ Zamak 4 properties

Property

! Metric value

! Imperial value

colspan=3| Mechanical properties[https://www.eazall.com/PublicDoc/ZincDie%20CastingPropertiesGuide2012.pdf]{{Citation |title=Zinc alloy mechanical characteristics |url=http://www.jinyialloy.com/en/productsmore.asp?id=6 |access-date=2008-03-01 |archive-url=https://web.archive.org/web/20120210185003/http://www.jinyialloy.com/en/productsmore.asp?id=6 |archive-date=2012-02-10 |url-status=dead}}
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

| colspan=2 align="center"| 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

| colspan=2 align="center"| 91 Brinell

colspan=3| Physical properties[https://www.eazall.com/PublicDoc/ZincDie%20CastingPropertiesGuide2012.pdf]{{Citation |title=Zinc alloy physical characteristics |url=http://www.jinyialloy.com/en/productsmore.asp?id=7 |access-date=2008-03-01 |archive-url=https://web.archive.org/web/20120210185008/http://www.jinyialloy.com/en/productsmore.asp?id=7 |archive-date=2012-02-10 |url-status=dead}}
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

| colspan=2 align="center"| 26-27% IACS

Specific heat capacity

| 418.7 J/kg-°C

| 0.100 BTU/lb-°F

Zamak 5

Zamak 5 has the same composition as zamak 3 with the addition of 1% copper in order to increase strength (by approximately 10%), hardness and corrosive resistance, but reduces ductility. It also has less dimensional accuracy. Zamak 5 is more commonly used in Europe.

class="wikitable"

|+ Zamak 5 composition per standard

! colspan=2|

! colspan=3|Alloying elements

! colspan=8|Impurities

Standard

! Limit

! Al

! Cu

! Mg

! Pb

! Cd

! Sn

! Fe

! Ni

! Si

! In

! Tl

! Zn

rowspan=2|ASTM B240 (Ingot)

| min

| 3.9

| 0.75

| 0.03

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 1.25

| 0.06

| 0.004

| 0.003

| 0.002

| 0.075

| -

| -

| -

| -

rowspan=2|ASTM B86 (Cast)

| min

| 3.5

| 0.75

| 0.03

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 1.25

| 0.06

| 0.005

| 0.004

| 0.003

| 0.1

| -

| -

| -

| -

rowspan=2|EN1774 (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

| -

| -

rowspan=2|EN12844 (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

| -

| -

rowspan=2|JIS H2201 (Ingot)

| min

| 3.9

| 0.75

| 0.03

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 1.25

| 0.06

| 0.003

| 0.002

| 0.001

| 0.075

| -

| -

| -

| -

rowspan=2|JIS H5301 (Cast)

| min

| 3.5

| 0.75

| 0.02

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 1.25

| 0.06

| 0.005

| 0.004

| 0.003

| 0.01

| -

| -

| -

| -

rowspan=2|AS1881

| 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

rowspan=2|GB8738-88

| min

| 3.9

| 0.7

| 0.03

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 1.1

| 0.06

| 0.004

| 0.003

| 0.0015

| 0.035

| -

| -

| -

| -

class="wikitable"

|+ Zamak 5 properties{{Citation|title=Zinc Die Casting Alloy Guide|url=https://www.eazall.com/PublicDoc/ZincDie%20CastingPropertiesGuide2012.pdf|access-date=2008-02-29}}

Property

! Metric value

! Imperial value

colspan=3| 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

| colspan=2 align="center"| 2%

Elongation at fracture

| colspan=2 align="center"| 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

| colspan=2 align="center"| 91 Brinell

Modulus of elasticity

| 96 GPa

| 14,000,000 psi

colspan=3| 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

| colspan=2 align="center"| 0.08

Zamak 7

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.

class="wikitable"

|+ Zamak 7 composition per standard

! colspan=2|

! colspan=3|Alloying elements

! colspan=8|Impurities

Standard

! Limit

! Al

! Cu†

! Mg

! Pb

! Cd

! Sn

! Fe

! Ni‡

! Si

! In

! Tl

rowspan=2|ASTM B240 (Ingot)

| min

| 3.9

| -

| 0.01

| -

| -

| -

| -

| -

| -

| -

| -

max

| 4.3

| 0.1

| 0.02

| 0.002

| 0.002

| 0.001

| 0.075

| -

| -

| -

| -

rowspan=2|ASTM B86 (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

| -

| -

| -

rowspan=2|GB8738-88

| min

| 3.9

| -

| 0.01

| -

| -

| -

| -

| 0.005

| -

| -

| -

max

| 4.3

| 0.1

| 0.02

| 0.002

| 0.002

| 0.001

| 0.075

| 0.02

| -

| -

| -

colspan=13| †Impurity ‡Alloying element

class="wikitable"

|+ Zamak 7 properties{{Citation| title = Zinc Alloy 7; AG40B; Zn-4Al-0.015Mg| url = http://www.matweb.com/search/DataSheet.aspx?MatID=14541 | access-date = 2008-02-29}}

Property

! Metric value

! Imperial value

colspan=3| 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

| colspan=2 align="center"| 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

| colspan=2 align="center"| 80 Brinell

colspan=3| 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

Common uses for zamak alloys include appliances, bathroom fixtures, die cast toys and automotive industry.{{cite web|url=https://en.amklassiek.nl/zamak-is-alloy/2017/08/14/|title=Zamak is an alloy|access-date=2023-08-26}}{{Cite web|url=https://www.fox360.net/technology/zamak-alloys-in-the-automotive-industry.html|title=Zamak Alloys in the automotive industry}}{{Citation| publisher = Met-Mex Peñoles S.A. | title = Metals: Zamak| url = http://www.penoles.com.mx/penoles/ingles/productos/metales/zamak.php | archive-url = https://web.archive.org/web/20080110170404/http://www.penoles.com.mx/penoles/ingles/productos/metales/zamak.php | archive-date = 2008-01-10 }} Zamak alloys are also used in the manufacture of some firearms such as those from Hi-Point Firearms.{{Cite web|url=https://www.breachbangclear.com/sw380-pocket-gun/|title = SW380 - Forgotten Pocket Gun That Should Stay Thataway|date = 3 April 2019}}{{Cite web|url=https://www.americanrifleman.org/content/pistol-caliber-pairing-hi-point-s-affordable-firearms/|title = An Official Journal of the NRA | Pistol-Caliber Pairing: Hi-Point's Affordable Firearms}} 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.Charles R. Stratton, British Enfield Rifles, Vol 2, North Cape Publications, 1999 and 2003, pages 106-107

See also

References

{{reflist|2}}

External links

  • {{usurped|1=[https://archive.today/20130118123306/http://www.brockmetal.com/page.asp?node=141&sec=Zinc_Alloy_Generic_Terms Generic Terms For Zinc Alloys]}}
  • [https://www.eazall.com/PublicDoc/ZincDie%20CastingPropertiesGuide2012.pdf Zinc Die Casting Alloy Guide]

Category:Zinc alloys