Zn-Cu alloys in die casting are regarded as a special branch for zinc die casting,which have been used in modern industrial manufacturing successfully. High Zn element content inside zinc alloy can enhance the strength, hardness and wear resistance of the cast parts at large extension, makes the cast parts more durable. Like some automotive components, luxurious goods accessories, industrial machinery parts. they need high strength, high wear resistance and high temperature resistance. So the requirement for Zn-Cu alloy in die casting become more popular.
Introduction Of Zn-Cu Alloys
Zn-Cu alloys(zinc–copper alloys) blong to a family of zinc-based materials which is added with other metal elements. Zn-Cu alloys focus on these zinc alloys, ZA-8,ZA-12, ZA-27. They contain different content of Cu element, lead to different metal properties Zn-Cu alloys.
| Zn-Cu Alloy | Cu Element Content(%) | Metal Property |
|---|---|---|
| ZA-8 | 1 | Slight improvement in strength and hardness |
| ZA-12 | 1 | Slight improvement in strength and hardness, more high corrosion resistance |
| ZA-27 | 2.5 | High hardness and wear resistance, moderate strength |
Zn-Cu Alloys In Die Casting Process Features
Zn-Cu alloys belong to low melting point metal alloys although these zinc alloys contain a bit content of Cu element. Significantly the Cu element contraints the fluidity of zinc alloys at lower temperature. So Zn-Cu alloys in die casting that contain higher Cu element content can not accept thin-walled cast parts and microminiature structural parts.
| Consumpting More Heat Energy To Melt Zn-Cu Alloys
Melting Zn-Cu alloys require consumpting more heat energy due to Cu element inside Zn-Cu alloys. These metal alloys are molten completely at 380-450℃. Compare to Zamak 2, Zamak 3 and Zamak 5, which are all low melting point zinc alloys, and are molten at 350-420℃. More Cu element content, More higher Temperature Required.
| More Higher Tooling Cost
The Tooling for Casting Zn-Cu alloys are suitable for hot chamber and cold chamber die casting. The Zn-Cu alloys that lower Cu element content allows hot chamber die casting, but that in which higher Cu element contenct requires cold chamber die casting. More higher temperature running, more wear of the tooling. This allows the cast die for casting the metal alloys should be high performance, and select premium quality tooling steel than Zamak serial alloys. Accordingly higher tooling cost is defined.
| Die Casting Process Compatibility
Die casting process for Zn-Cu alloys is compatible for hot chamber and cold chamber die casting due to different Cu content between ZA-8,ZA-12 and ZA-27. Depends on different metal alloys, die casting manufacturer designs and manufactures different performance cast dies and meeting high efficiency mass production at high volume. Lower Cu content metal alloys require hot chamber die casting machine to process, Like ZA-8, while ZA-12 and ZA-27 is favor of cold chamber die casting one.
| Improved Hardness Of Cast Parts
Although Zn-Cu alloys die Casting are higher than Zamak alloys, the cast part has an improved hardness. These cast parts become more strong strength, but a bit brittleness if too high Cu content inside the metal alloys. Like ZA-8, ZA-12 and ZA-27, which have excellent hardness and strength, makes the cast parts more wear resistance and impact repetive.
| Enhanced Wear Resistance & Mechanical Performance
Zinc cast parts for casting Zn-Cu alloys have an enhanced wear resistance and higher mechanical performance. Since Cu element enhance the hardness, strength and creep resistance of the metal alloys. Different formula metal alloys generate different metal properties. Like these Zn-Cu alloys , which be made into high hardness automotive components, protective housings and high-temperature resistance components.
| Constraint of Fluidity, Impact Microstructure Cast Parts
Cu element has a bad fluidity, which constraints the fluidity of zinc alloys. Everyone knows that zinc die casting is suitable for precision miniature parts,which is for Zamak serial alloys. while Zn-Cu alloys maybe are considered for medium and large sized cast parts. High Cu element content possiblely contraints the flow speed of the molten metal, even through reject some microstructure cast parts and thin-walled cast parts.
With the change of die casting process technique, the specific functional cast parts are created, the tooling for casting metal alloys become high cost. Like Zn-Cu alloys in die casting require preminum performance cast die to accept repetive wear at higher temperature and finish mass prodcution at high efficiency at high volume.
Zn-Cu Alloys In Die Casting is Used In Industries
Zn-Cu alloys in die casting have been made into various metal cast parts and applied in many fields. From the below list have a brief.
- Auomotive Components: Lock core, transmmision housings, integrated structrural supporting frames.
- Luxurious Good Accessories: brand Label, zipper headers.
- Industrial Equipment Components: gearing,
- Consumer Goods: bathroom hardwares, furniture fittings, power tool housings.
- Hardware & Construction: Door handles and locks, hinges and decorative hardwares.
- Electronics & Communication Components: Shielding enclosures, heat dissipation components, 5G structural parts
Conclusion
In summary, Zn-Cu alloys in die casting can meet some specific requirements in some fields. Their features are good hardness and strength and excellent wear resistance. Like some automotive components, such as door lock components, gear housings and bracket and bear-loading structural parts. Industrial equipment components, such as Gears and worm wheels, Bushings and bearings and pump and valve parts.
