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Zamak

From Wikipedia, the free encyclopedia
Zamak ingot

ZAMAK(orZamac,formerlytrademarkedasMAZAK[1]) is a family ofalloyswith a base metal ofzincand alloying elements ofaluminium,magnesium,andcopper.

Zamak alloys are part of thezinc aluminiumalloy family; they are distinguished from the other ZA alloys because of their constant 4% aluminium composition.[2]

The namezamakis anacronymof theGermannames for themetalsof which the alloys are composed:Zink(zinc),Aluminium,MagnesiumandKupfer(copper).[2]TheNew Jersey Zinc Companydeveloped 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 commonlydie cast.[2]Zamak alloys (particularly #3 and #5) are frequently used in thespin castingindustry.

A large problem with early zinc die casting materials waszinc pest,owing to impurities in the alloys.[3]Zamak avoided this by the use of 99.99% pure zinc metal, produced byNew Jersey Zinc'suse of arefluxeras part of therefiningprocess.

Zamak can be electroplated, wet painted, andchromate conversion coatedwell.[4]

Mazak

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In the early 1930s,Morris Ashbyin 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 nameMazak,partly to distinguish it from zamak and partly from the initials of Morris Ashby. In 1933,National Smeltinglicensed the refluxer patent with the intent of using it to produce 99.99% zinc in their plant atAvonmouth.[5]It is colloquially known among UK car restoration hobbyists asmonkey metal.

Standards

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

Zinc alloy standards per country[6]
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:

Various names for zamak alloys
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

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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 asKirksitewhen gravity cast for use as adie.[2][18]It was originally designed for low volume sheet metal dies.[19][20]It later gained popularity for making short runinjection moldingdies.[19]It is also less commonly used for non-sparking tools andmandrelsfor metal spinning.

Zamak 2 composition per standard
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 - - - -
Zamak 2 properties[17]
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 5x108cycles) 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 4.7x10−5BTU/lb
Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F
Coefficient of friction 0.08

KS

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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 theorange peeleffect.[25]

KS composition[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 - - - -
KS properties[25]
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

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Zamak 3 is thede facto standardfor 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]

Zamak 3 composition per standard
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
Zamak 3 properties[4]
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 5x108cycles) 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 4.7x10−5BTU/lb
Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F
Coefficient of friction 0.07

Zamak 4

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Zamak 4 was developed for the Asian markets to reduce the effects ofdie solderingwhile maintaining the ductility of zamak 3. This was achieved by using half the amount of copper from the zamak 5 composition.[27]

Zamak 4 composition per standard
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 - - - -
Zamak 4 properties
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 5x108cycles) 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

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Zamak 5 has the same composition as zamak 3 with the addition of 1% copper in order to increase strength (by approximately 10%[17]),hardnessand corrosive resistance, but reducesductility.[30]It also has less dimensional accuracy.[30]Zamak 5 is more commonly used in Europe.[2]

Zamak 5 composition per standard
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 - - - -
Zamak 5 properties[30]
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 5x108cycles) 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 4.7x10−5BTU/lb
Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F
Coefficient of friction 0.08

Zamak 7

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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]

Zamak 7 composition per standard
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 - - -
ImpurityAlloying element
Zamak 7 properties[31]
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 5x108cycles) 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

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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 fromHi-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

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References

[edit]
  1. ^Zamak Latest Status Info,retrieved2008-03-02
  2. ^abcdefghiDiecasting Alloys,retrieved2008-03-02
  3. ^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 fromthe original(PDF)on 2011-07-16.
  4. ^abZL3/ZL0400/ZnAl4 (Zamak 3),retrieved2008-02-29
  5. ^Cocks, E.J.; Walters, B. (1968),A History of the Zinc Smelting Industry in Britain,Harrap,ISBN0-245-59377-2.
  6. ^World wide zinc die casting standards,Nyrstar,retrieved2008-02-25.
  7. ^abcNow defunct due to standardization of European countries under EN 1774 & EN 12844.
  8. ^abcdefghijklmnopASTM B86-04e2(PDF),2004-10-01,retrieved2008-02-10
  9. ^abcdefghijklmnopASTM B240-98(PDF),1998-05-01,retrieved2008-02-10
  10. ^Semiatin, S. L. (2006).ASM Handbook, Volume 14B: Metalworking: Sheet Forming.ASM International.ISBN978-0-87170-710-9.
  11. ^abcdefghijklmnoAlloy designation - cross reference table(PDF),archived fromthe original(PDF)on 2011-07-08,retrieved2010-10-31
  12. ^abcdefghiGB8738 - Chinese standard: zinc alloys ingots for casting (2006),retrieved2008-02-27
  13. ^abcdefghiZN-004,archived fromthe originalon 2012-02-10,retrieved2008-03-01
  14. ^abcdJIS H2201 - Japanese Industrial Standard - Zinc alloy ingot for die casting (1999),retrieved2008-02-26
  15. ^abcdJIS H5301 - Japanese Industrial Standard - Zinc alloy die casting (1979),retrieved2008-02-26
  16. ^zamak 4 (Alloy 4),retrieved2008-03-01
  17. ^abcZL2/ZL0430/ZnAl4Cu3 (Zamak 2),retrieved2008-02-29
  18. ^Husite Engineering - Benefits of Cast Kirksite Tooling,archived fromthe originalon March 1, 2022,retrievedApril 19,2011
  19. ^abArmstrong, Paul J.; Petch, Bill,Cast Kirksite Re-Emerges as RT Approach for Molding Plastics,retrieved2008-03-15.
  20. ^Parker, Dana T.Building Victory: Aircraft Manufacturing in the Los Angeles Area in World War II,p. 86, 119, 120, Cypress, CA, 2013.ISBN978-0-9897906-0-4.
  21. ^abcdASTM B240: Standard specification for zinc in ingot form for die casting: chemical composition,retrieved2008-02-27
  22. ^abcdASTM B86: Standard specification for zinc die casting: chemical composition,retrieved2008-02-27
  23. ^abcEN1774 Standard - zinc and zinc alloys - alloys for foundry purposes - ingot and liquid,retrieved2008-02-27
  24. ^abcEN12844: Standard - zinc and zinc alloys - castings - specification (September 1998),retrieved2008-02-27
  25. ^abcKS (spin casting alloy),retrieved2008-03-15
  26. ^abAS1881 - Australia standard - Zinc alloys - casting ingots and casting requirements (1986),retrieved2008-02-27
  27. ^zamak 4 (Alloy 4),retrieved2008-03-09
  28. ^[1]Zinc alloy mechanical characteristics,archived fromthe originalon 2012-02-10,retrieved2008-03-01
  29. ^[2]Zinc alloy physical characteristics,archived fromthe originalon 2012-02-10,retrieved2008-03-01
  30. ^abcZinc Die Casting Alloy Guide(PDF),retrieved2008-02-29
  31. ^Zinc Alloy 7; AG40B; Zn-4Al-0.015Mg,retrieved2008-02-29
  32. ^"Zamak is an alloy".Retrieved2023-08-26.
  33. ^"Zamak Alloys in the automotive industry".
  34. ^Metals: Zamak,Met-Mex Peñoles S.A., archived fromthe originalon 2008-01-10
  35. ^"SW380 - Forgotten Pocket Gun That Should Stay Thataway".3 April 2019.
  36. ^"An Official Journal of the NRA | Pistol-Caliber Pairing: Hi-Point's Affordable Firearms".
  37. ^Charles R. Stratton, British Enfield Rifles, Vol 2, North Cape Publications, 1999 and 2003, pages 106-107
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