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Zamak

ZAMAK (or Zamac, formerly trademarked as MAZAK[1]) is a family of alloys with a base metal of zinc and alloying elements of aluminium, magnesium, and copper.

Zamak ingot

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.

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 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 refining process.

Zamak can be electroplated, wet painted, and chromate conversion coated well.[4]

Mazak edit

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.[5] It is colloquially known among UK car restoration hobbyists as monkey metal.

Standards edit

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 edit

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 as Kirksite when gravity cast for use as a die.[2][18] It was originally designed for low volume sheet metal dies.[19][20] 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
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 5x108 cycles) 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 4.7x10−5 BTU/lb
Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F
Coefficient of friction 0.08

KS edit

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.[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 edit

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.[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 5x108 cycles) 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 4.7x10−5 BTU/lb
Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F
Coefficient of friction 0.07

Zamak 4 edit

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.[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 5x108 cycles) 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 edit

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 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 5x108 cycles) 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 4.7x10−5 BTU/lb
Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F
Coefficient of friction 0.08

Zamak 7 edit

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 - - -
Impurity Alloying 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 5x108 cycles) 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 edit

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 from Hi-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 edit

References edit

  1. ^ Zamak Latest Status Info, retrieved 2008-03-02
  2. ^ a b c d e f g h i Diecasting Alloys, retrieved 2008-03-02
  3. ^ Wanhill, R.J.H.; Hattenberg, T. (May 2005), (PDF), National Aerospace Laboratory NLR, NLR-TP-2005-205, archived from the original (PDF) on 2011-07-16.
  4. ^ a b ZL3/ZL0400/ZnAl4 (Zamak 3), retrieved 2008-02-29
  5. ^ Cocks, E.J.; Walters, B. (1968), A History of the Zinc Smelting Industry in Britain, Harrap, ISBN 0-245-59377-2.
  6. ^ World wide zinc die casting standards, Nyrstar, retrieved 2008-02-25.
  7. ^ a b c Now defunct due to standardization of European countries under EN 1774 & EN 12844.
  8. ^ a b c d e f g h i j k l m n o p ASTM B86-04e2 (PDF), 2004-10-01, retrieved 2008-02-10
  9. ^ a b c d e f g h i j k l m n o p ASTM B240-98 (PDF), 1998-05-01, retrieved 2008-02-10
  10. ^ Semiatin, S. L. (2006). ASM Handbook, Volume 14B: Metalworking: Sheet Forming. ASM International. ISBN 978-0-87170-710-9.
  11. ^ a b c d e f g h i j k l m n o (PDF), archived from the original (PDF) on 2011-07-08, retrieved 2010-10-31
  12. ^ a b c d e f g h i GB8738 - Chinese standard: zinc alloys ingots for casting (2006), retrieved 2008-02-27
  13. ^ a b c d e f g h i ZN-004, retrieved 2008-03-01
  14. ^ a b c d JIS H2201 - Japanese Industrial Standard - Zinc alloy ingot for die casting (1999), retrieved 2008-02-26
  15. ^ a b c d JIS H5301 - Japanese Industrial Standard - Zinc alloy die casting (1979), retrieved 2008-02-26
  16. ^ zamak 4 (Alloy 4), retrieved 2008-03-01
  17. ^ a b c ZL2/ZL0430/ZnAl4Cu3 (Zamak 2), retrieved 2008-02-29
  18. ^ Husite Engineering - Benefits of Cast Kirksite Tooling, retrieved April 19, 2011
  19. ^ a b Armstrong, Paul J.; Petch, Bill, Cast Kirksite Re-Emerges as RT Approach for Molding Plastics, retrieved 2008-03-15.
  20. ^ Parker, Dana T. Building Victory: Aircraft Manufacturing in the Los Angeles Area in World War II, p. 86, 119, 120, Cypress, CA, 2013. ISBN 978-0-9897906-0-4.
  21. ^ a b c d ASTM B240: Standard specification for zinc in ingot form for die casting: chemical composition, retrieved 2008-02-27
  22. ^ a b c d ASTM B86: Standard specification for zinc die casting: chemical composition, retrieved 2008-02-27
  23. ^ a b c EN1774 Standard - zinc and zinc alloys - alloys for foundry purposes - ingot and liquid, retrieved 2008-02-27
  24. ^ a b c EN12844: Standard - zinc and zinc alloys - castings - specification (September 1998), retrieved 2008-02-27
  25. ^ a b c KS (spin casting alloy), retrieved 2008-03-15
  26. ^ a b AS1881 - Australia standard - Zinc alloys - casting ingots and casting requirements (1986), retrieved 2008-02-27
  27. ^ zamak 4 (Alloy 4), retrieved 2008-03-09
  28. ^ [1]Zinc alloy mechanical characteristics, retrieved 2008-03-01
  29. ^ [2]Zinc alloy physical characteristics, retrieved 2008-03-01
  30. ^ a b c Zinc Die Casting Alloy Guide (PDF), retrieved 2008-02-29
  31. ^ Zinc Alloy 7; AG40B; Zn-4Al-0.015Mg, retrieved 2008-02-29
  32. ^ "Zamak is an alloy". Retrieved 2023-08-26.
  33. ^ "Zamak Alloys in the automotive industry".
  34. ^ , Met-Mex Peñoles S.A., archived from the original on 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

External links edit

  • Generic Terms For Zinc Alloys
  • Zinc Die Casting Alloy Guide

zamak, zamak, zamac, formerly, trademarked, mazak, family, alloys, with, base, metal, zinc, alloying, elements, aluminium, magnesium, copper, ingot, alloys, part, zinc, aluminium, alloy, family, they, distinguished, from, other, alloys, because, their, constan. ZAMAK or Zamac formerly trademarked as MAZAK 1 is a family of alloys with a base metal of zinc and alloying elements of aluminium magnesium and copper Zamak ingotZamak 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 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 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 refining process Zamak can be electroplated wet painted and chromate conversion coated well 4 Contents 1 Mazak 2 Standards 3 Zamak 2 3 1 KS 4 Zamak 3 5 Zamak 4 6 Zamak 5 7 Zamak 7 8 Uses 9 See also 10 References 11 External linksMazak editIn 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 5 It is colloquially known among UK car restoration hobbyists as monkey metal Standards editZinc alloy chemical composition standards are defined per country by the standard listed below Zinc alloy standards per country 6 Country Zinc ingot Zinc castingEurope EN1774 EN12844US ASTM B240 ASTM B86Japan JIS H2201 JIS H5301Australia AS 1881 SAA H63 AS 1881 SAA H64China GB 8738 88 Canada CSA HZ3 CSA HZ11International 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 OtherZamak 2 8 9 orKirksite 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 editZamak 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 as Kirksite when gravity cast for use as a die 2 18 It was originally designed for low volume sheet metal dies 19 20 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 ImpuritiesStandard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In TlASTM 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 valueMechanical propertiesUltimate tensile strength 397 MPa 331 MPa aged 58 000 psiYield strength 0 2 offset 361 MPa 52 000 psiImpact 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 psiCompressive yield strength 641 MPa 93 000 psiFatigue strength reverse bending 5x108 cycles 59 MPa 8 600 psiHardness 130 Brinell 98 Brinell aged Modulus of elasticity 96 GPa 14 000 000 psiPhysical propertiesSolidification range melting range 379 390 C 714 734 FDensity 6 8 kg dm3 0 25 lb in3Coefficient of thermal expansion 27 8 mm m C 15 4 min in FThermal conductivity 105 W m K 729 BTU in hr ft2 FElectrical resistivity 6 85 mW cm at 20 C 2 70 mW in at 68 FLatent heat heat of fusion 110 J g 4 7x10 5 BTU lbSpecific heat capacity 419 J kg C 0 100 BTU lb FCoefficient of friction 0 08KS edit 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 25 KS composition 25 Alloying elements ImpuritiesStandard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In TlNyrstar 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 valueMechanical propertiesUltimate tensile strength lt 200 MPa lt 29 000 psiYield strength 0 2 offset lt 200 MPa lt 29 000 psiElongation lt 2 Hardness 150 Brinell maxPhysical propertiesSolidification range melting range 380 390 C 716 734 FDensity 6 6 g cm3 0 25 lb in3Coefficient of thermal expansion 28 0 mm m C 15 4 min in FThermal conductivity 105 W m K 729 BTU in hr ft2 FElectrical conductivity 25 IACSSpecific heat capacity 419 J kg C 0 100 BTU lb FCoefficient of friction 0 08Zamak 3 editZamak 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 2 Zamak 3 composition per standard Alloying elements ImpuritiesStandard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In TlASTM 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 001GB8738 88 12 min 3 9 0 03 max 4 3 0 1 0 06 0 004 0 003 0 0015 0 035 ImpurityZamak 3 properties 4 Property Metric value Imperial valueMechanical propertiesUltimate tensile strength 268 MPa 38 900 psiYield strength 0 2 offset 208 MPa 30 200 psiImpact 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 psiCompressive yield strength 414 MPa 60 000 psiFatigue strength reverse bending 5x108 cycles 48 MPa 7 000 psiHardness 97 BrinellModulus of elasticity 96 GPa 14 000 000 psiPhysical propertiesSolidification range melting range 381 387 C 718 729 FDensity 6 7 g cm3 0 24 lb in3Coefficient of thermal expansion 27 4 mm m C 15 2 min in FThermal conductivity 113 W mK 784 BTU in hr ft2 FElectrical resistivity 6 37 mW cm at 20 C 2 51 mW in at 68 FLatent heat heat of fusion 110 J g 4 7x10 5 BTU lbSpecific heat capacity 419 J kg C 0 100 BTU lb FCoefficient of friction 0 07Zamak 4 editZamak 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 27 Zamak 4 composition per standard Alloying elements ImpuritiesStandard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In TlNingbo 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 valueMechanical properties 28 Ultimate tensile strength 317 MPa 46 000 psiYield strength 0 2 offset 221 269 MPa 32 000 39 000 psiImpact strength 61 J 7 J aged 45 ft lbf 5 ft lbf aged Elongation 7 Shear strength 214 262 MPa 31 000 38 000 psiCompressive yield strength 414 600 MPa 60 000 87 000 psiFatigue strength rotary bending 5x108 cycles 48 57 MPa 7 000 8 300 psiHardness 91 BrinellPhysical properties 29 Solidification range melting range 380 386 C 716 727 FDensity 6 6 g cm3 0 24 lb in3Coefficient of thermal expansion 27 4 mm m C 15 2 min in FThermal conductivity 108 9 113 0 W m K 100 C 755 6 784 0 BTU in hr ft2 F 212 FElectrical conductivity 26 27 IACSSpecific heat capacity 418 7 J kg C 0 100 BTU lb FZamak 5 editZamak 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 elements ImpuritiesStandard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl ZnASTM 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 001GB8738 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 valueMechanical propertiesUltimate tensile strength 331 MPa 270 MPa aged 48 000 psi 39 000 psi aged Yield strength 0 2 offset 295 MPa 43 000 psiImpact 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 psiCompressive yield strength 600 MPa 87 000 psiFatigue strength reverse bending 5x108 cycles 57 MPa 8 300 psiHardness 91 BrinellModulus of elasticity 96 GPa 14 000 000 psiPhysical propertiesSolidification range melting range 380 386 C 716 727 FDensity 6 7 kg dm3 0 24 lb in3Coefficient of thermal expansion 27 4 mm m C 15 2 min in FThermal conductivity 109 W mK 756 BTU in hr ft2 FElectrical resistivity 6 54 mW cm at 20 C 2 57 mW in at 68 FLatent heat heat of fusion 110 J g 4 7x10 5 BTU lbSpecific heat capacity 419 J kg C 0 100 BTU lb FCoefficient of friction 0 08Zamak 7 editZamak 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 ImpuritiesStandard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In TlASTM 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 Impurity Alloying elementZamak 7 properties 31 Property Metric value Imperial valueMechanical propertiesUltimate tensile strength 285 MPa 41 300 psiYield strength 0 2 offset 285 MPa 41 300 psiImpact strength 58 0 J 42 8 ft lbfElongation at fracture 14 Shear strength 214 MPa 31 000 psiCompressive yield strength 414 MPa 60 000 psiFatigue strength reverse bending 5x108 cycles 47 0 MPa 6 820 psiHardness 80 BrinellPhysical propertiesSolidification range melting range 381 387 C 718 729 FCoefficient of thermal expansion 27 4 mm m C 15 2 min in FThermal conductivity 113 W m K 784 BTU in hr ft2 FElectrical resistivity 6 4 mW cm 2 5 mW inSpecific heat capacity 419 J kg C 0 100 BTU lb FCasting temperature 395 425 C 743 797 FUses editCommon 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 from Hi 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 editPot metal Babbitt alloy References edit Zamak Latest Status Info retrieved 2008 03 02 a b c d e f g h i Diecasting Alloys retrieved 2008 03 02 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 from the original PDF on 2011 07 16 a b ZL3 ZL0400 ZnAl4 Zamak 3 retrieved 2008 02 29 Cocks E J Walters B 1968 A History of the Zinc Smelting Industry in Britain Harrap ISBN 0 245 59377 2 World wide zinc die casting standards Nyrstar retrieved 2008 02 25 a b c Now defunct due to standardization of European countries under EN 1774 amp EN 12844 a b c d e f g h i j k l m n o p ASTM B86 04e2 PDF 2004 10 01 retrieved 2008 02 10 a b c d e f g h i j k l m n o p ASTM B240 98 PDF 1998 05 01 retrieved 2008 02 10 Semiatin S L 2006 ASM Handbook Volume 14B Metalworking Sheet Forming ASM International ISBN 978 0 87170 710 9 a b c d e f g h i j k l m n o Alloy designation cross reference table PDF archived from the original PDF on 2011 07 08 retrieved 2010 10 31 a b c d e f g h i GB8738 Chinese standard zinc alloys ingots for casting 2006 retrieved 2008 02 27 a b c d e f g h i ZN 004 retrieved 2008 03 01 a b c d JIS H2201 Japanese Industrial Standard Zinc alloy ingot for die casting 1999 retrieved 2008 02 26 a b c d JIS H5301 Japanese Industrial Standard Zinc alloy die casting 1979 retrieved 2008 02 26 zamak 4 Alloy 4 retrieved 2008 03 01 a b c ZL2 ZL0430 ZnAl4Cu3 Zamak 2 retrieved 2008 02 29 Husite Engineering Benefits of Cast Kirksite Tooling retrieved April 19 2011 a b Armstrong Paul J Petch Bill Cast Kirksite Re Emerges as RT Approach for Molding Plastics retrieved 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 a b c d ASTM B240 Standard specification for zinc in ingot form for die casting chemical composition retrieved 2008 02 27 a b c d ASTM B86 Standard specification for zinc die casting chemical composition retrieved 2008 02 27 a b c EN1774 Standard zinc and zinc alloys alloys for foundry purposes ingot and liquid retrieved 2008 02 27 a b c EN12844 Standard zinc and zinc alloys castings specification September 1998 retrieved 2008 02 27 a b c KS spin casting alloy retrieved 2008 03 15 a b AS1881 Australia standard Zinc alloys casting ingots and casting requirements 1986 retrieved 2008 02 27 zamak 4 Alloy 4 retrieved 2008 03 09 1 Zinc alloy mechanical characteristics retrieved 2008 03 01 2 Zinc alloy physical characteristics retrieved 2008 03 01 a b c Zinc Die Casting Alloy Guide PDF retrieved 2008 02 29 Zinc Alloy 7 AG40B Zn 4Al 0 015Mg retrieved 2008 02 29 Zamak is an alloy Retrieved 2023 08 26 Zamak Alloys in the automotive industry Metals Zamak Met Mex Penoles S A archived from the original on 2008 01 10 SW380 Forgotten Pocket Gun That Should Stay Thataway 3 April 2019 An Official Journal of the NRA Pistol Caliber Pairing Hi Point s Affordable Firearms Charles R Stratton British Enfield Rifles Vol 2 North Cape Publications 1999 and 2003 pages 106 107External links editGeneric Terms For Zinc Alloys Zinc Die Casting Alloy Guide Retrieved from https en wikipedia org w index php title Zamak amp oldid 1172302591, wikipedia, wiki, book, books, library,

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