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Introduction
Zinc alloy is widely specified for die casting because there is no other plastic production material with specific properties. But even when choosing a material for die casting, assessing mechanical properties per the requirements of the project is imperative. In this article, we will examine the mechanical properties of zinc alloy and compare it to other metals that are commonly used in die casting, including aluminum, magnesium, brass, and stainless steel.
List the mechanical properties of Zinc alloy
Zinc alloy has a low melting point, requiring less energy to cast, and has a high fluidity supplying thin walled intricate parts. Zinc alloy brasses characteristics It is good with bearing and wear resistance, so it is suitable for bearings. Common zinc alloys like Zamak (composed of aluminum, magnesium, and copper) provide the benefit of adequate strength, impact resistance, and corrosion resistance. As a die casting metal, it provides competitive tensile properties and hardness, measuring at approximately 250–400 MPa and 90–120 BHN, respectively, for most zinc alloys.
Comparing with other die casting materials
Aluminum Alloys
The most significant benefit of aluminum alloys is the combination of high strength-to-weight ratio and excellent thermal conductivity. Compared to, zinc alloys have greater tensile strength (250–750 MPa) compared to aluminum alloys (80-500 MPa), and in general aluminum alloys have a lower level of ultimate tensile strength. In addition to its relatively superior density, which is much lower than that of zinc alloy, thereby making it light and suitable for lightweight applications, aluminum is lacking when it comes to wear resistance and also has poor wear resistance performance.
Magnesium Alloys
It is one of the lightest, as well as very high strength magnesium alloys and it can possess about 150–350 MPa of tensile strength. Not to mention, great corrosion resistance and high recyclability. But high reactivity makes magnesium alloys costly and sometimes even difficult to cast, which leads to the limited applications in die-casting.
Brass
Brass is a copper-zinc alloy that provides good corrosion resistance and malleability. It is denser than zinc alloy, and the mechanical properties of brass, such as the yield tensile strength (300-Alloy-500 MPa), can be similar but can vary widely depending on the actual brass alloy used. Brass being good looking and less prone to tarnish is used frequently.
Stainless Steel
Everybody knows stainless steel strength, stainless steel anti-corrosion ability, and stainless steel durability. It gives excellent hardness and high tensile strength [400–1600 MPa] along with a higher cost and higher casting temperature compared to zinc alloy. Stainless steel is often used in extreme industries and environments where durability and corrosion resistance need to be a top priority.
Effect of Die Casting Process on Engineering Properties
Fabrication of Zinc Alloy The mechanical properties of zinc alloy are significantly affected by die casting process. Microstructure and hence properties of the final part are dependent on a variety of factors such as die temperature and section thickness. Controlled change of the microstructure of the alloy over time is called ageing and can enhance some mechanical properties (greater tensile strength and hardness).
Uses of Zinc die casting and where to use the zinc alloy
Zinc alloy is the most widely used metal in vehicle parts, hardware, electric/electronic products, and other applications that require components with a blend of strength, durability, and economy. When we look at zinc alloy and metal alternatives for some applications, we have to consider the cost of metal, weight and necessary mechanical properties. For instance, aluminium is ideal for low load components whilst zinc alloy is used for components in exposure to more severe service conditions.
Conclusion
Zinc alloy offers a cost-effective combination of dies casting mechanical properties. Although not always the most robust or lightweight alternative—its relatively good property profile, low cost, and simple casting among others continues to be an appealing to many manufacturers. Choosing zinc alloy for die casting needs to be based on need in applications such as requirements on mechanical properties, cost-level, and capabilities in the process. With continued developments in alloys of zinc however, we can only expect requisite performance improvements, widening the field of applications in which zinc alloy is the material of choice.