THE CAPABILITIES OF ZINC DIE CASTING

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1 THE CAPABILITIES OF ZINC DIE CASTING Presented by: Ryan Winter (Manager Customer Engineering Services) Eastern Alloys, Inc.

2 Eastern Alloys, Inc.

3 Introduction to ZINC

4 Introduction to Zinc Zinc is the 4th most consumed metal in the word after steel, Aluminum & Copper.

5 Source (2000): Introduction to Zinc

6 Introduction to Zinc

7 Introduction to Zinc - Galvanizing

8 Introduction to Zinc Die Casting

9 Introduction to Zinc Die Casting

10 Zinc Alloys & Specifications

11 Alloy Composition (ASTM Designation) ELEMENT Aluminum Magnesium ZAMAK ALLOYS No.2 No.3 No.5 No Copper Nickel Note: Values in weight % Hot Chamber Pressure Die Casting

12 Alloy Composition (ASTM Designation) ELEMENT Aluminum Magnesium ZAMAK ALLOYS No.2 No.3 No.5 No ZA ALLOYS ZA-8 ZA-12 ZA Copper Nickel Hot Note: Values in weight % Hot Chamber Pressure Die Casting Chamber Cold Chamber Gravity Casting

13

14 Specifications Specifying Specification Country International U.S.A. Canada Japan U.K. Australia Organization ISO ASTM CSA JIS CEN SAS Ingots Castings B 240 B 86 HZ.3 HZ.11 H 2201 H 5301 EN 1776 AS 1881

15 Zamak 3 Alloy Element Aluminum Magnesium Copper (max) Iron (max) Lead (max) Cadmium (max) Tin (max) Zinc (99.99%) Composition (wt%) Alloy Ingot Die Casting (ASTM B240) (ASTM B86) Balance Balance

16 Zamak 3 Alloy Element Aluminum Magnesium Copper (max) Iron (max) Lead (max) Cadmium (max) Tin (max) Zinc (99.99%) Composition (wt%) Alloy Ingot Die Casting (ASTM B240) (ASTM B86) RoHS requirements: Lead content below % Cadmium content below 0.01% Balance Balance

17 Zinc Die Casting Process

18 Advantages of Zinc Die Casting In a nutshell Higher Volumes Cost Savings by Casting Net Shape: Consolidating Parts Eliminate Machining Cost Savings due to Low Melting Temp: Low Energy Costs Lower Tooling Costs Fast Cycle Times Enhanced Properties Fast solidification First Costs are not Last Costs

19 Zinc Pressure Die Casting Conventional

20 Zinc Pressure Die Casting Conventional Hot Chamber Machine Die Halves Plunger Metal Pump (Gooseneck)

21

22 Zinc Pressure Die Casting Miniature

23 Zinc Pressure Die Casting Miniature

24 Other Casting Processes Involving Zinc Alloys Sand Casting Low Volumes Permanent Mold: Cast Iron Graphite Slush Casting Spin Casting Investment Casting Etc.

25 Zinc Die Casting Advantages (Hot Chamber) - Recap Faster Cycle Times - Hot Chamber vs. Cold Chamber Longer Die Life - Approx 1,000,000 vs. 100,000 (10 to 1) Less Porosity Lower Energy Costs More Complex shapes - Eliminate Machining Net Shape Consolidate parts Designing considerations: Less draft requirement, Thinner walls, etc

26 Selection of Zinc Alloys Properties of Zinc Die Castings

27

28 First Costs are not Last Costs

29 1 Examples of Density

30

31

32

33 Thermal Conductivity BTU/ft-hr. F Zamak 3 Zamak 5 ZA-8 ZA-12 ZA-27 A380 Al 6063 T6 AZ-91D Mg C83600 Brass Grey Fe 0 Zinc Alloys Other Metals Plastics

34

35

36

37

38 Harder, Better, Faster Stronger

39

40 First Costs are not Last Costs

41

42

43

44 Bearing Ware Rate 8 7 Applied Stress = 6.9 Mpa mg/hr ZA27 - (S.C.) ZA27 - (D.C.) ZA12 - (D.C.) ZA8 - (D.C.) Zamak 3 (D.C.) C95200 Al-Bronze (S.C.) C93200 Pb-Sn-Bronze (S.C.) 0 Zinc Alloys Bronze

45

46 Actuator couplers for Brake Transmission System Actuator couplers - die cast Zinc die cast couplers met the durability and manufacturing requirements and were fully qualified in time, allowing steering column production to start on schedule.

47 Replacing an investment cast steel design, for substantial cost savings in cable shift cam. Cable Shift Cam

48 Replacing a two-part powder metal pinion hub (powdered metal). Pinion Hub

49 Window Regulating Mechanism Many vehicles use a window lift mechanism consisting of a machined steel spindle with a gear on one end, a knurl on the other, and a Zamak 3 die casting retainer. The spindle is made on location, and then shipped to another facility where the retainer is cast around it. The final design is made as a single, low-cost, netshaped, hot-chamber die casting.

50 Eastern Alloys Information Phone: Website: Bar stock info (prototyping):

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