Zamak

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Zamak ingot Zamak (formerly trademarked as ZAMAK[1] and also known as Zamac) is a 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.[2] The name zamak is an acronym of the German names for the metals of which the alloys are composed: Zink (zinc), Aluminium, Magnesium and Kupfer (copper).[2] The New Jersey Zinc Company developed zamak alloys in 1929. While zinc alloys are popularly referred to as pot metal or white metal, zamak is held to higher industrial standards. The most common zamak alloy is zamak 3, but zamak 2, zamak 5 and zamak 7 are still commercially used.[2] These alloys are most commonly die cast.[2] 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.[3] 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 smelting process. Zamak can be electroplated, wet painted, and chromate conversion coated well.[4]

Contents

1 Mazak 2 Standards 3 Zamak 2 o 3.1 KS 4 Zamak 3 5 Zamak 4 6 Zamak 5

7 Zamak 7 8 Uses 9 References 10 External links

Mazak
In the early 1930s Morris Ashby in Britain had licensed the New Jersey zamak alloy. The highpurity 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.[5]

Standards
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 USA 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 Short UK Traditio Short Europe For Comm AST Chin BS nal composit an JIS m on M a 1004 name ion name designat [7] ion Zamak 2[8][9] AG ZnAl4Cu Ing Alloy ZL0430[ or 43A[8 11] [11] [8][9] 3 ot 2 ][9] Kirksite[
10]

ZX04
[12]

Franc Germ e any Oth NFA DIN UNS er 55- 1743010[7] 2[7] ZL2 , ZZAZ430[1 Z3554 A4U3 1] 2, 0[9] [11] ZN002[
13]

Cas t

ZP0430

ZP2, ZAZ3554 2, 1[8] ZN002[

13]

Ing ot Zamak 3[8][9] ZnAl4[11] AG Alloy 40A[8 [8][9] 3 ][9] Cas t

ZL0400[
11]

Ingot ZX01 type [12] [14] 2 Allo ZZ400[1 y [11] 1] A4 A[11]

ZL3 , ZAZ3552 3, 1[9] ZN003[

13]

ZP0400

ZDC2
[15]

ZP3, ZAZ3352 3, 0[8] ZN003[

13]

Zamak 4[16]

Ing Used in Asia only ot

ZA4, ZN004[
13]

Ing ot Zamak 5[8][9] ZnAl4Cu 1[11] Cas t AG Alloy 41A[8 5[8][9] ][9]

ZL0410[
11]

Ingot ZX03 type [12] 1[14] Allo ZZ410[1 y A4UI[ 1] B[11] 11]

ZL5 , ZAZ3553 5, 0[9] ZN005[

13]

ZP0410

ZDC1
[15]

ZP5, ZAZ3553 5, 1[8] ZN005[

13]

Zamak 7[8][9]

AG ZnAl4Ni[ Alloy 40B[8 12] [8][9] 7 ][9] Cas t

Ing ot

ZX02
[12]

Z3352 ZA2[9] 7, ZNZ3352 007[ 13] 3[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 aluminium (04= 4% aluminium) 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 less elastic.[17] Zamak 2 is also known as Kirksite when gravity cast for use as a die.[2][18] It was originally designed for low volume sheet metal dies.[19] It later gained popularity for making short run injection molding dies.[19] It is also less commonly used for non-sparking tools and mandrels for metal spinning. Zamak 2 composition per standard Alloying elements Impurities Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl min 3.9 2.6 0.025 - ASTM B240[20] (Ingot) max 4.3 2.9 0.05 0.004 0.003 0.002 0.075 - min 3.5 2.6 0.025 - ASTM B86[21] (Cast) max 4.3 2.9 0.05 0.005 0.004 0.003 0.1 - min 3.8 2.7 0.035 - EN1774[22] (Ingot) max 4.2 3.3 0.06 0.003 0.003 0.001 0.02 0.001 0.02 - min 3.7 2.7 0.025 - EN12844[23] (Cast) max 4.3 3.3 0.06 0.005 0.005 0.002 0.05 0.02 0.03 - min 3.9 2.6 0.03 - GB8738-88[12] max 4.3 3.1 0.06 0.004 0.003 0.0015 0.035 - Property Ultimate tensile strength Yield strength (0.2% offset) Impact strength Zamak 2 properties[17] Metric value Mechanical properties 397 MPa (331 MPa aged) 361 MPa 38 J (7 J aged) English value 58,000 psi 52,000 psi 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 8 Fatigue strength (reverse bending 5x10 59 MPa 8,600 psi cycles) Hardness 130 Brinell (98 Brinell aged) Modulus of elasticity 96 GPa 14,000,000 psi Physical properties Solidification range (melting range) 379390 C 714734 F 3 Density 6.8 kg/dm 0.25 lb/in3 Coefficient of thermal expansion 27.8 m/m-C 15.4 in/in-F Thermal conductivity 105 W/m-K 729 BTU-in/hr-ft2-F Electrical resistivity 6.85 -cm at 20 C 2.70 -in at 68 F Latent heat (heat of fusion) 110 J/g 4.7x105 BTU/lb Specific heat capacity 419 J/kg-C 0.100 BTU/lb-F Coefficient of friction 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.[24] KS composition[24] Alloying elements Impurities Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl min 3.8 2.5 0.4 - - - Nyrstar max 4.2 3.5 0.6 0.003 0.003 0.001 0.020 - - - KS properties[24] Property Metric value English 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) 380390 C 716734 F Density 6.6 g/cm3 0.25 lb/in3

Coefficient of thermal expansion Thermal conductivity Electrical conductivity Specific heat capacity Coefficient of friction

28.0 m/m-C 15.4 in/in-F 105 W/m-K 729 BTU-in/hr-ft2-F 25% IACS 419 J/kg-C 0.100 BTU/lb-F 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% aluminium). 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 Impurities elements Cu Mg Pb Cd Sn Fe Ni Si In Tl 0.025 0.1 0.05 0.004 0.003 0.002 0.075 0.025 0.25 0.05 0.005 0.004 0.003 0.1 0.035 0.03 0.06 0.003 0.003 0.001 0.02 0.001 0.02 0.025 0.1 0.06 0.005 0.005 0.002 0.05 0.02 0.03 0.03 0.03 0.06 0.003 0.002 0.001 0.075 0.02 0.25 0.06 0.005 0.004 0.003 0.01 0.04 0.03 0.06 0.003 0.003 0.001 0.05 0.001 0.0005 0.001 0.03 0.1 0.06 0.004 0.003 0.0015 0.035 Zamak 3 properties[4] Metric value Mechanical properties 268 MPa 208 MPa

Limit Al min 3.9 ASTM B240 (Ingot) max 4.3 [21] min 3.5 ASTM B86 (Cast) max 4.3 min 3.8 EN1774[22] (Ingot) max 4.2 min 3.7 EN12844[23] (Cast) max 4.3 [14] min 3.9 JIS H2201 (Ingot) max 4.3 [15] min 3.5 JIS H5301 (Cast) max 4.3 min 3.9 AS1881[25] max 4.3 min 3.9 GB8738-88[12] max 4.3 Impurity
[20]

Standard

Property Ultimate tensile strength Yield strength (0.2% offset)

English value 38,900 psi 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 8 Fatigue strength (reverse bending 5x10 cycles) 48 MPa 7,000 psi Hardness 97 Brinell Modulus of elasticity 96 GPa 14,000,000 psi Physical properties Solidification range (melting range) 381387 C 718729 F 3 Density 6.7 g/cm 0.24 lb/in3 Coefficient of thermal expansion 27.4 m/m-C 15.2 in/in-F Thermal conductivity 113 W/mK 784 BTU-in/hr-ft2-F Electrical resistivity 6.37 -cm at 20 C 2.51 -in at 68 F Latent heat (heat of fusion) 110 J/g 4.7x105 BTU/lb Specific heat capacity 419 J/kg-C 0.100 BTU/lb-F Coefficient of friction 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.[26] Zamak 4 composition per standard Alloying Impurities elements Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl min 3.9 0.3 0.03 max 4.3 0.5 0.06 0.003 0.002 0.002 0.075 min 3.9 0.3 0.04 max 4.2 0.4 0.05 0.003 0.002 0.001 0.02 0.001 0.02 0.0005 0.001 Zamak 4 properties Metric value English value [28] Mechanical properties 317 MPa 46,000 psi 221269 MPa 32,00039,000 psi 61 J (7 J aged) 45 ft-lbf (5 ft-lbf aged) 7%

Standard Ningbo Jinyi Alloy Material Co.[13] Genesis Alloys Ltd.[27]

Property Ultimate tensile strength Yield strength (0.2% offset) Impact strength Elongation

Shear strength Compressive yield strength Fatigue strength (rotary bending 5x108 cycles) Hardness

214262 MPa 414600 MPa 4857 MPa

[29]

31,00038,000 psi 60,00087,000 psi 7,0008,300 psi 91 Brinell

Physical properties Solidification range (melting range) 380386 C 716727 F 3 Density 6.6 g/cm 0.24 lb/in3 Coefficient of thermal expansion 27.4 m/m-C 15.2 in/in-F 108.9113.0 W/m-K @ 755.6784.0 BTU-in/hr-ft2-F Thermal conductivity 100 C @ 212 F Electrical conductivity 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%[17]), hardness and corrosive resistance, but reduces ductility.[30] It also has less dimensional accuracy.[30] Zamak 5 is more commonly used in Europe.[2] Zamak 5 composition per standard Alloying Impurities elements Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl Zn min 3.9 0.75 0.03 max 4.3 1.25 0.06 0.004 0.003 0.002 0.075 min 3.5 0.75 0.03 max 4.3 1.25 0.06 0.005 0.004 0.003 0.1 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 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 min 3.9 0.75 0.03 max 4.3 1.25 0.06 0.003 0.002 0.001 0.075 min 3.5 0.75 0.02 max 4.3 1.25 0.06 0.005 0.004 0.003 0.01 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 min 3.9 0.7 0.03 -

Standard ASTM B240[20] (Ingot) ASTM B86[21] (Cast) EN1774[22] (Ingot) EN12844[23] (Cast) JIS H2201[14] (Ingot) JIS H5301[15] (Cast) AS1881[25] GB8738-88[12]

max 4.3 1.1 Property Ultimate tensile strength

0.06

0.004 0.003 0.0015 0.035 [30]

Yield strength (0.2% offset) Impact strength Elongation at Fmax Elongation at fracture Shear strength 262 MPa Compressive yield strength 600 MPa 8 Fatigue strength (reverse bending 5x10 57 MPa 8,300 psi cycles) Hardness 114 Brinell Modulus of elasticity 96 GPa 14,000,000 psi Physical properties Solidification range (melting range) 380386 C 716727 F 3 Density 6.7 kg/dm 0.24 lb/in3 Coefficient of thermal expansion 27.4 m/m-C 15.2 in/in-F Thermal conductivity 109 W/mK 756 BTU-in/hr-ft2-F Electrical resistivity 6.54 -cm at 20 C 2.57 -in at 68 F Latent heat (heat of fusion) 110 J/g 4.7x105 BTU/lb Specific heat capacity 419 J/kg-C 0.100 BTU/lb-F Coefficient of friction 0.08

Zamak 5 properties Metric value Mechanical properties 331 MPa (270 MPa aged) 295 MPa 52 J (56 J aged)

English value

48,000 psi (39,000 psi aged) 43,000 psi 38 ft-lbf (41 ft-lbf aged) 2% 3.6% (13% aged) 38,000 psi 87,000 psi

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.[2] Zamak 7 composition per standard Alloying elements Impurities Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl min 3.9 0.01 - - ASTM B240[20] (Ingot) max 4.3 0.1 0.02 0.002 0.002 0.001 0.075 - - min 3.5 0.005 0.005 - - ASTM B86[21] (Cast) max 4.3 0.25 0.02 0.003 0.002 0.001 0.075 0.02 - - -

min 3.9 max 4.3 0.1 Impurity Alloying element GB8738-88[12]

0.01 0.02

0.005 - - 0.002 0.002 0.001 0.075 0.02 - - -

Zamak 7 properties[31] Property Metric value English 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 8 Fatigue strength (reverse bending 5x10 cycles) 47.0 MPa 6,820 psi Hardness 80 Brinell Physical properties Solidification range (melting range) 381387 C 718729 F Coefficient of thermal expansion 27.4 m/m-C 15.2 in/in-F Thermal conductivity 113 W/m-K 784 BTU-in/hr-ft2-F Electrical resistivity 6.4 -cm 2.5 -in Specific heat capacity 419 J/kg-C 0.100 BTU/lb-F Casting temperature 395425 C 743797 F