Zinc Alloys.

Metal Quality and Composition.

Introduction






Background:


Zinc alloy pressure die-casting has been a recognised manufacturing process
since the early 1900s, at which time it was common practice to add impurities
such as lead, tin, antimony and others. It was generally believed that these
additions improved the casting properties of the alloy. These were added
without any knowledge of their long or short-term effects on the alloy
properties.


The whole pattern of thought changed in the 1920- 30s when research by the
New Jersey Zinc company proved that certain impurities were detrimental to
long term stability of the alloy structure. This in turn had a major effect on the
mechanical properties and performance of zinc alloy pressure die-castings.


This work broadly established the current alloy specification. In particular, the
need to control certain impurities and the use of special high grade zinc as the
prime feedstock for alloy manufacture. The research has continued and has
led to a consistent refinement of world Zinc alloy standards.


All Brock Zinc alloys are produced to exacting standards and therefore it is
important for the user to maintain the alloy chemistry by careful process and
good working practice.







THE BROCK METAL COMPANY LIMITED, WALSALL ROAD, NORTON CANES, CANNOCK, STAFFS. UK. WS11 9NR.
Zinc Alloys.
Metal Quality and Composition.

Alloy specifications




The specification of the zinc alloys are not arbitrary, in fact, zinc alloys are
unique in their requirement for purity and the need for rigid control of
chemistry.

This needs to be maintained because:

The specification has a major influence on the properties of the
alloy range.

The market trends show a need for an improved quality
standard and consistency in alloy quality.

The reputation of the zinc alloy die-casting industry depends on
our commitment to these standards.

The objective of this section of the manual is to establish what can go wrong in
the melting process, why and how to avoid the problems.



Alloy Ingot Specification.

Hot chamber die-casting alloys.


Alloy/Element Aluminium Magnesium Copper
ZL 2 3.8 - 4.2% 0.035 -0.06% 2.7 3.3%
ZL 3 3.8 - 4.2% 0.035 -0.06% 0.03% max
ZL 5 3.8 - 4.2% 0.035 -0.06% 0.7 1.1%
ZL 8 8.2 8.8% 0.02 0.03% 0.9 1.3%




THE BROCK METAL COMPANY LIMITED, WALSALL ROAD, NORTON CANES, CANNOCK, STAFFS, UK. WS11 9NR.

Zinc Alloys.
Metal Quality and Composition.

Alloy chemistry.


.





It has been proved by research and many years of international practical
application that the specification overleaf offers:

Consistent mechanical properties.
Excellent casting properties.
Good finishing properties.
Long term quantifiable casting performance.

BS EN 1774: 1999. Specifies that the alloy ingot must identify;

The alloy producer by name.
The alloy type
The individual melt reference.

This information guarantees that any individual batch of material is traceable
and that it conforms to a recognised quality regime.
___________________________

The EN standards were introduced to ensure that all European countries work
to the same recognised standards. EN 1774 refers only to the supply of ingot,
which is a departure from the now defunct BS 1004 standard. As from 1999
all zinc alloy castings should comply with the requirements of BS EN 12844;
1999.

EN 1774 also contains one other major departure from BS 1004 in that it
removes the requirement to use SHG zinc in the manufacture of all zinc
pressure die-casting alloys. It is essential to understand that the control of
feed stock still exists and that the bulk of zinc alloy used in die-casting will still
be manufactured from primary zinc due to the unavailability of volume
secondary materials.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD, NORTON CANES, CANNOCK, STAFFS, UK. WS11 9NR.


Zinc Alloys.
Metal Quality and Composition.

Alloy chemistry.



Alloying elements.

Zinc:

All Brock pressure die-casting alloys are manufactured from what is known as SHG
zinc or super high grade zinc. This material is a priced commodity on the London
Metal Exchange (LME) and therefore being traded by dealers its price fluctuates
throughout any trading period.
SHG zinc is 99.995% pure and its chemistry is governed by EN 1179:1996. The bulk
of SHG used within the UK is imported from inside Europe as either ingot of 15Kgs or
1 tonne jumbo blocks. As pure zinc is a soft, ductile material with low mechanical
properties other materials are added to improve its mechanical properties. Zinc also
has one other undesirable feature it will dissolve iron at certain temperatures. The
addition of these elements control and reduce these effects.




Specific Alloying Elements.

Aluminium:
This element is added to improve the strength and casting fluidity. It also reduces the
leaching or dissolving effect of pure zinc on the cast iron machine components and is
therefore an essential element. The specified levels of aluminium give the best
combination of mechanical properties casting characteristics.
It is important to remember that levels of aluminium below 3.5% will result in:
Lower mechanical properties.
Poor surface finish.
Hot shortness at the casting stage.
Above a 4.5%
Mechanical properties deteriorate markedly.
Particularly impact strength, which drops dramatically.
It should be noted that overheating of zinc alloy will deplete aluminium levels and this
must be avoided at all costs.




THE BROCK METAL COMPANY LIMITED, WALSALL ROAD, NORTON CANES, CANNOCK, STAFFS, UK. WS11 9NR.


Zinc Alloys.
Metal Quality and Composition.

Alloy chemistry.



Alloying elements.

Copper:

Copper is a contaminant in ZL 3 and is restricted to 0.1% in the new EN specification.

It is controlled within the whole alloy range because it introduces dimensional
instability in castings. For this reason, ZL 3 will give the best dimensional stability
within the zinc pressure die-casting alloy range.

Generally:
Copper increases hardness and improves fluidity.
Improve mechanical properties such as tensile strength.

But:
Copper has a tendency to cause grain growth in castings at copper levels
above 1%. This will only be evident where extremely accurate and
consistent dimensional control is required in a casting application.

Magnesium:

The main function of magnesium additions is to counteract the effects of harmful
impurities in the alloy. Some of which cause inter-granular corrosion, a problem,
which can seriously affect the short and long term properties of zinc alloy castings.

In addition, magnesium is used to:
Increase strength and hardness.
Reduce the impact embrittlement temperatures.
It is important to control the levels present in the alloy because:
Even at the specified levels, it reduces fluidity.
It will increase dross if excessive amounts are present.
It tends to increase hot shortness at the casting stage.
It must be remembered that overheating will cause depletion of magnesium
levels and this must be avoided at all costs.




THE BROCK METAL COMPANY LIMITED, WALSALL ROAD, NORTON CANES, CANNOCK, STAFFS, UK. WS11 9NR.


Zinc Alloys.
Metal Quality and Composition.

Alloy impurities.



Some impurities are present at the alloy manufacture stage as all feed stocks used
contain minute levels of trace impurities. These are controlled by the use of SHG and
the application of good practice within the smelter. However, impurities or
contaminants are usually increased within the die-casting plant and this increase
originates from:

Bad house keeping.
Poor foundry practice.
Lack of basic knowledge and understanding.

The most common impurities encountered in the foundry are:
Excess copper, chromium and nickel.
Iron.
Lead tin and cadmium.
Silicon and manganese.

Impurity levels quoted by the current standard are as follows:

Element Pb Cd Sn Fe Ni Si

ZP 3 .005% .005% .002% .05% .02% .03%
ZP 5 .005% .005% .002% .05% .02% .03%
ZP 2 .005% .005% .002% .05% .02% .03%
ZP 8 .006% .006% .003% .06% .02% .045%

It is essential that these impurities are controlled because:
They all have detrimental effects on the properties of the alloy.
They have a direct effect on casting quality and process performance.
They alter the long term stability of the casting.
They change the finishing and machining characteristics of the alloy.

Next, these impurities are discussed in detail to explain the problems associated with
each type of contamination.






THE BROCK METAL COMPANY LIMITED, WALSALL ROAD, NORTON CANES, CANNOCK, STAFFS, UK. WS11 9NR.


Zinc Alloys.
Metal Quality and Composition.

Alloy impurities.



Specific Impurities.
Iron:

Probably, the most common impurity evident in poorly controlled foundries.
Source:
Most common leaching or pick up from the machine pot.
Less common contaminated swarf, or foreign bodies dropped into the pot.

Effects:
Depleted aluminium levels.
Increased dross levels.
Poor machinability.(excessive levels)
Poor castability.
Difficult polishing, hard spots after plating etc.

Prevention:
Good temperature control allied to instrument calibration programme.
Regular pot inspection procedures.
Maintenance of alloy pot levels.
Good house keeping.



Silicon and Manganese:
Source:
Usually originates from contaminated aluminium mixed in with zinc foundry
returns (Frequent in foundries using both zinc and aluminium alloys.)
Leaching from the iron holding pots. (Would be accompanied by high iron
levels).
Effect:
High levels of either element reduce machinability and increase dross.
Similar to high iron.
Prevention:
Good material handling and segregation procedures.
Similar measures as adopted for iron.



THE BROCK METAL COMPANY LIMITED, WALSALL ROAD, NORTON CANES, CANNOCK, STAFFS, UK. WS11 9NR.


Zinc Alloys.
Metal Quality and Composition.

Alloy impurities.




Specific Impurities.
Iron:

Copper, Nickel and Chromium.
Source:
Contaminated foundry returns.(ZP 3 +ZP 5 or ZP2)
Poor control of reprocessing plated parts.
Effects:
Excess copper will put ZP 3 parts out of specification and will affect the
properties of ZP 5 parts.
Could affect the casting properties and dimensional stability,.
In extreme cases could cause casting difficulties.
Prevention:
Always re-melt plated foundry scrap separately and analyse the resulting
ingot before use.
Preferably, use a refiner alloyer to re-melt plated scrap or sell off as reject
material.
Both nickel and chrome have low solubility in zinc alloys due to the melt temperature.
Therefore, it is difficult to have excessive contamination as these elements tend to
float to the surface of the melt and can be skimmed off with the resulting dross.

Lead, Tin and Cadmium.
Source:
Lead lumps and hammers.
Solder, white metal bearings.
Leaded Brass rod, bronze bearings.
Plated castings Tin or cadmium.
Effect:
High Risk contaminant - very serious not to be ignored.
Cause inter-granular corrosion.
At 0.2% lead levels will cause casting to disintegrate in very short period.
Some embrittlement may be evident after casting.
Prevention:
Prohibit the use of any lead or lead bearing tools within the factory.
Good housekeeping.
Make operatives aware of potential costs.
Magnesium will control effects while these impurities remain within
specification.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD, NORTON CANES, CANNOCK, STAFFS, UK. WS11 9NR.