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ZINC ALLOY INGOT

Phoenix Industries Ltd is India’s leading Zinc Alloy Ingot manufacturer, supplier and exporter that offers complete range of zinc die casting alloys. The name ZAMAK/MAZAK draws upon the basic metallurgy of the alloy group: Z-Zinc, A-Aluminum, MA-Magnesium, and Cu-copper. In India as well as world wide, Zinc Alloys are the most common alloys used for hot chamber die casting with a combination of superior mechanical properties and low melting/manufacturing costs. They fulfil the need for most die casting applications. Other ZAMAK alloys include ZAMAK 2, ZAMAK-3, ZAMAK 5, and ZAMAK 7/12/27, High Purity Die Casting Alloys Special Alloys for galvanizing Aluminium 10/20/30/40 Al/Ni Al/Sn/Sb Al/Misc. Metal Alloys. Today there are two ACuZinc alloys: ACuZinc 5 (5% Copper), and ACuZinc 10 (10% Copper), and are used in a variety of automotive applications. ACuZinc 5 is a hot chamber die cast due to its lower melting temperature, whereas ACuZinc 10 is cold chamber die cast.

Zinc Die cast Ingot

Diecast products are used in things we use everyday and also find application in daily a wide range of industrial fields such as automobiles, machine parts, building parts and furniture parts. Our zinc diecast ingot is used for making diecast products and containing proper metals such as AI influences on the physical property of the product.

OUR ZINC ALLOYS

Alloy Al Mg Cu Fe Pb Cd Sn Ni Zn
Zamak 2 3.9-4.3 0.025-0.050 2.6-2.9 0.075 Max 0.003 Max 0.003 Max 0.002 Max - BAL
Zamak 3 3.9-4.3 0.025-0.050 0.10 Max 0.075 Max 0.003 Max 0.003 Max 0.002 Max - BAL
Zamak 5 3.9-4.3 0.03-0.06 0.75-1.25 0.075 Max 0.003 Max 0.003 Max 0.002 Max - BAL
Zamak 7 3.9-4.3 0.01-0.02 0.1 Max 0.075 Max 0.003 Max 0.002 Max 0.001 Max 0.005-0.020 BAL
ZA 8 8.0-8.8 0.015-0.030 0.8-1.3 0.1 Max 0.003 Max 0.003 Max 0.002 Max - BAL
ZA 12 10.5-11.5 0.015-0.030 0.5-1.25 0.075 Max 0.003 Max 0.003 Max 0.002 Max - BAL
ZA 27 25.0-28.0 0.010-0.020 2.0-2.5 0.1 Max 0.003 Max 0.003 Max 0.002 Max - BAL

Advantages

We provide personal casting design assistance to the end-user or die caster.
Product Designers specify zinc castings for several important reasons

Applications

ZA 2

A predecessor of the more widely used ZA 2, it has the highest strength and hardness in the Zinc - 4% aluminium die casting alloy family. Because of its relatively high copper content, it is about 25% stronger as cast than ZA 3, and almost 10% stronger than ZA 5, with higher hardness than either. The high copper content, however necessitates segregation of trim scrap.

After aging, the alloy retains tensile strength better than the other alloys in the group and becomes more dimensionally stable, but it gives up impact strength and loses hardness. Because of these limitations, ZA 2 is used only when the strength or hardness of ZA 3 or ZA 5 are not sufficient for the end use. This alloy is recommended only where casting design cannot provide enough strength with ZA 5 or where increased hardness is required.

ZA 3
Of all the Zinc casting alloys, ZA 3 is the most widely used, accounting for some 85% of all zinc casting tonnage. Its excellent physical and mechanical properties, excellent castibility and long-term dimensional stability provide the basis for its broad usage. The ease with which it can be electroplated adds to the popularity of this alloy. Where properties comparable to or better than those of aluminum alloys are required, Alloy ZA-8, ZA-12, or ZA-27 should be considered.
ZA 5
Most often, through casting design procedures, an ZA 3 pressure die-casting can be made to meet service or functional requirements. When this is not the case, especially where strength is concerned, ZA 5 is the logical choice. Except for a nominal 1% copper addition the chemistry of ZA 5 is comparable to that of ZA 3. This composition modification results in higher tensile strength and increased hardness, with a sacrifice in elongation. ZA 5 also has significantly better creep resistance than the other alloys in the conventional group.

ZA 5 is not as ductile as some of the other alloys, a factor to consider when post-casting operations are required. Because of the copper content, trim scrap should be segregated.
ZA 7
The third most popular alloy is a high purity, low magnesium alloy called No. 7. This alloy has improved fluidity (because of the lower magnesium content) allowing it to be cast at lower temperatures for better as-cast surface finish and higher production rates. ZA 7 is mostly used in decorative hardware applications. Since it possesses slightly more ductility than other zinc alloys. No. 7 is also used where castings require severe deformation in assembly operations.

The successful use of No. 7 alloy requires good control of metal, die and nozzle temperatures to avoid excessive flash. Because of the increased ductility flash tends to bend over instead of break off in vibratory deburning and better fits may be required on trim dies to obtain a clean trim.
ZA 8
Of all the zinc alloys that can be cast in hot-chamber machines, ZA-8 is the most creep resistant (three times that of ZA 3) and is the strongest and hardest. It is used principally in structural or highly stressed applications. In spite of its relatively high aluminium content, it can be electroplated using conventional 0' plating techniques.
ZA 12
Excellent castibility in cold-chamber die casting machines, coupled with outstanding properties, including low density and superior creep strength, makes ZA-12 a high performance material that is suitable for use with all casting processes. Its superior wear properties make it possible, in some situations, to eliminate costly inserts in die-castings which otherwise are required to provide bearing or wear surfaces.

The alloy can be electroplated. Intensification (applying a high pressure to overcome sluggish feeding behavior after the die is filled) can be beneficial, but is not considered necessary.
ZA 27
The strongest, hardest and lightest of all the zinc pressure die casting alloys, ZA-27 also has the best wear properties and is among the most creep resistant. However, it is the most difficult to electroplate. Sand cast parts can be heat-treated to increase ductility. Because of its higher melting range compared with ZA-8 and ZA-12. It requires longer cycle times. As with ZA-12, ZA-27, is specified for high-performance applications when conventional zinc or aluminium alloys are inadequate. In many cases, both of these ZA alloys may be substituted directly for aluminium using existing tooling. They also can be continuously and centrifugally cast for bearings and machine parts.

COMPARISION OF ZINC CASTING ALLOY PROPERTIES
CHEMICAL SPECIFICATION (PER ASTM)

Alloy #2 #3 #5 #7 ZA 8 ZA 12 ZA 27
Ingot Ingot Casting Ingot Casting Ingot Casting Ingot Ingot Ingot
Al 3.9-4.3 3.9-4.3 3.5-4.3 3.9-4.3 3.5-4.3 3.9-4.3 3.5-4.3 8.0-8.8 10.5-11.5 25.0-28.0
Mg .025-.050 .025-.050 .02-.05 .03-.06 .03-.08 .01-.02 .005-.020 .015-.30 .015-.030 .010-.020
Cu 2.6-2.9 .10 max .25 max .75-1.25 .75-1.25 .10 max .25 max 0.8-1.3 0.5-1.25 2.0-2.5
 Fe (max) 0.075 0.075 0.1 0.075 0.1 0.075 0.075 0.1 0.075 0.1
Pb (max) 0.006 0.006 0.007 0.006 0.007 0.004 0.005 0.006 0.006 0.006
Cd (max) 0.003 0.003 0.004 0.003 0.004 0.002 0.002 0.003 0.003 0.003
Sn (max) 0.002 0.002 0.003 0.002 0.003 0.001 0.001 0.002 0.002 0.002
Ni - - - - - .005-.020 .005-.020 - - -
Zn Balance Balance Balance Balance Balance Balance Balance Balance Balance Balance
DENSITY (Kg/m3) 6000 6000 6700 6600 6300 6030 5000
MELTING RANGE °C 379-390 382-387 381-386 381-387 375-404  377-432 376-484
ELECTRICAL
CONDUCTIVITY (% IACS)		 25 27 26 27 27.7 28.3 29.7
THERMAL CONDUCTIVITY
(w/m/hr./m2/k) 		 104.7 113 109 113 114.7 116.1 125.5
COEF. OF THERMAL EXPANSION
(20-100 C) trim m/m m °k) 		 27.8 27.4 27.4 27.4 23.3 24.1 26
SPECIFIC HEAT (j/kg/°k) 419 419 419 419 435 450 525

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