Due to the sustainable properties of zinc and the manufacturing process, zinc die casting continues to gain importance. Zinc die casting enables the implementation of complex geometries with thin wall thicknesses at high reproducibility in tight tolerances and with high strength values. Quality and quality monitoring are crucial in the process chain - from the standard-compliant zinc die casting alloy to the finished castings. High-quality zinc die casting products require continuous quality monitoring - from the alloy, through the zinc die casting process, surface treatment, to the finished product.
Zinc Die Casting Alloys
The alloys ZP0400, ZP0410, ZP0430, which were developed using the zinc die casting process back in the early 1930s, have become particularly popular in practice. They form the basis for the development of furtherzinc die casting alloys, for special applications such as very thin-walled casting or for the optimization of special surface properties. The alloys are based on fine zinc with a purity of 99.995 percent zinc. Pure aluminum, copper and magnesium are further components that significantly influence the property profile of the alloys: Copper improves tensile strength and hardness, and magnesium prevents intergranular corrosion. Aluminum favors the workability of the zinc as well as the most important service properties, i.e. tensile strength, elongation at break and impact bending strength. At the same time, aluminum drastically reduces the reactivity of ferrous materials in contact with the liquid melt at temperatures below 450 degrees Celsius. As a result, all zinc-aluminum alloys can be processed in the fast and highly productive hot-chamber die casting process.
Most zinc die casting applications in Germany today are carried out in ZP0410. The second most commonly used alloy, ZP0430, has a higher tensile strength due to its higher copper content and is harder. It is used in many die casting applications with particular frictional stresses, but also in tool and die making. Alloy ZP0400 is characterized by good physical and mechanical properties. It is used mainly in English-speaking countries and is preferred where dimensional stability is important. Alloy ZP 0810 is the alternative to ZP0430 and is also frequently used in the English-speaking world, with mechanical properties comparable to those of alloy ZP0430.
