Exploiting the potential of modern zinc die-casting alloys

Zinc die-casting alloys can be produced quickly, precisely, and in a resource-efficient manner—but until now, they have rarely been used for high-stress applications. Researchers at Fraunhofer LBF have now investigated the cyclic material behavior and developed a design concept that paves the way for durable, sustainable components made of zinc – as a high-performance and fully recyclable alternative to plastic and aluminum.

“Flowchart for component lifetime calculation, divided into three main sections: Simulation input data (FEM analysis, casting process simulation), Experimental input data (stress-strain curve, damage fatigue curve, statistical influences, mean stress sensitivity, casting process effects), and calculation models (notch root stress analysis, local stress-strain behavior, damage calculation with linear damage accumulation). Source: Fraunhofer LBF — The new design concept for evaluating the service life of cyclically stressed components made of die-cast zinc increases their potential for use.

Zinc die-casting alloys can be produced quickly and in large quantities thanks to the efficient hot-chamber die-casting process. Due to their high surface quality, they are used in numerous industries – for example, for housings, connecting elements, or structural components. However, reliable fatigue strength data for applications subject to high cyclic loads has been lacking until now. Researchers at the Fraunhofer Institute for Structural Durability and System Reliability LBF have now closed this gap and investigated the cyclic material behavior of various zinc die-casting alloys. The results have been summarized in a new design concept.

Analysis of cyclic material behavior

In the “ZynkGuss” research project, the Fraunhofer team analyzed the material behavior of the Zamak 5 (ZP0410) alloy, taking into account stress-mechanical and technological influences. Fatigue strength tests showed that the local microstructure created during the die casting process has a decisive influence on the service life of thin-walled components.

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Design concept for service life assessment

The concept developed in the project combines the results of cyclic investigations with data from the casting process simulation. This will enable the production of highly stressed components from modern zinc die-cast alloys in the future. The findings are also being incorporated into guidelines and standards to make them widely available for use in industry.

Zinc die casting as a sustainable material alternative

The completion of the project marks an important step toward establishing zinc die casting alloys in demanding applications. The materials are fully recyclable without any loss of quality, offering great potential in terms of the circular economy. Industries such as automotive manufacturing, building technology, and the security and packaging industries can benefit from the new findings. Modern zinc die-casting alloys are considered a high-performance and sustainable alternative to plastics – and already meet future EU requirements for environmental compatibility and resource efficiency.