The Importance of Zinc Alloy
Composition and Control
The development of zinc die casting alloys
over the years has yielded the commonly used
alloys presently in service today: 3, 5 and 7.
Through the research programs, the chemical
compositions of these alloys have been set to
yield good mechanical properties, excellent
castability and fine finishing characteristics.
Extensive studies were performed to define
compositional limits so that aged mechanical
properties, dimensional stability and corrosion
resistance would meet the needs of the die
casting marketplace. Development of industry-
wide standards for the alloys and die castings
produced from zinc alloys has aided in making
zinc alloy die castings accepted by consumers
for engineered and decorative applications.
Occasionally, questions arise as to why the
stringent specifications for impurities and alloy-
ing elements exist. This article will serve to
refresh memories on the significance of strict
alloy control.
Aluminum content of castings is held at 3.5-
4.3%. In this range the mechanical properties
and castability of the alloys are the best. At
higher aluminum levels, impact strength drops
dramatically (from 40 ft-lb to 1 ft-lb). Aluminum
content under 3.5% lowers mechanical proper-
ties, promotes hot shortness and reduces sur-
face finish quality. The aluminum content also
reduces the rate of attack by the alloy on shot
end components and formation of oxide dross
on the molten bath surface.
Magnesium serves a two-fold role in zinc die
casting alloys. In the range of .01% to .08%
(depending upon alloy) magnesium increases
hardness and strength as well as lowers the
impact embrittlement temperature. However,
higher magnesium can result in hot shortness
(the reduction in strength of a casting when it is
ejected from the tool) as well as reduce fluidity
and tensile ductility. The primary role of mag-
nesium is to ensure that intergranular corrosion
will not occur when die cast components are in
high humidity environments. In the case of #7
alloy, magnesium content is controlled at a low
level (.005-.020%) to enhance fluidity, with a
nickel addition made (.005-.020%) to provide
additional corrosion resistance.
While copper is considered an impurity in #3
(with a limit of .25% permitted in castings), it is
added to #5 alloy to provide increased tensile
strength and hardness. However, during ele-
vated temperature aging, zinc die casting alloys
containing over 1.25% Cu are dimensionally
Reprinted from The Alloyer. No. 3, 1983.
Eastern Alloys Inc. PO Box Q Maybrook. NY 12543
unstable with growth up to .004/ and they lose stressed. The photographs below dramatically
tensile ductility and impact strength. show how these impurities can adversely affect
Generally, the control of alloying elements in zinc die castings. High lead can cause brittle-
the alloys is not difficult. Proper melting and ness and loss of ductility immediately after die
casting temperatures (less than 820F) good casting. A dropped casting can shatter due to
control of remelt practices and avoiding the use high lead. With aging or in high humidity envir-
of cleaning fluxes will insure that chemical onments, high lead, tin and cadmium will cause
composition is held within specification. intergranular (subsurface) corrosion which
Of the impurities associated with zinc die results in swelling, cracking, and distortion of
casting alloys, lead, tin, cadmium, iron, chrom- castings. Accelerated aging in 950 C steam
ium and silicon are the elements which are most allows short term evaluation of the effects of
likely to be encountered in a die casting plant. high impurities. The photograph shows the re-
Molten zinc and zinc alloys attack iron to vary- sults of a four day steam test. Contaminated
ing degrees. The addition of aluminum to the castings have disintegrated while those within
level used in the common die casting alloys specifications are intact. The cover plate shown
permits their use in hot chamber die casting in the second photograph was in service for
machines at the normal casting temperatures several years, but a lead content of about 0.2%
(less than 82OOF). The slow dissolution of iron caused the swelling and cracking and led to the
from ladles, pots and goosenecks at casting premature failure of the cover.
temperatures forms an aluminum-iron inter- The detrimental effect of impurities has been
metallic which floats to the surface and can be widely documented. For the die caster, impurity
skimmed off. Excessively high holding or nozzle control insists that good housekeeping be prac-
temperatures lead to increased iron dissolution ticed to keep tramp elements out of zinc alloys.
which can then produce excessive dross, drop- Questionable scrap should not be remelted,
ping the aluminum content of the alloy. In addi- and floor sweepings which can contain harmful
tion, high iron in the alloy leads to a reduction in impurities should not be indiscriminately re-
fluidity which can result in poor surface quality melted. All personnel should be made aware of
castings which may be brittle and present the consequences of high impurities. Outside
machining difficulty. Chromium is often picked workers must be informed that their materials
up by remelting plated scrap. Its solubility in must be kept out of scrap bins and melting fur-
zinc alloys is low, and when present at higher naces A plumber soldering water lines can
levels, acts like iron, forming intermetallics with easily contaminate a melting pot by disposing of
aluminum which then float off as dross. In die scrap lead-tin solder.
casting plants where aluminum alloys are also In conclusion, it is vital that the die caster pro-
cast, aluminum scrap mixed in with zinc returns cess alloy which meets ASTM ingot specifica-
are the primary source of silicon. Silicon can tion B240 as indicated below. He must insure
cause a loss of impact strength and machining that his in-house practices do not result in alloy
difficulties. contamination and that castings shipped meet
The effect of lead, tin and cadmium at levels ASTM B86 specification to preclude the possi-
above the ASTM specification cannot be over- bilities of field failures due to elevated impurity
levels.
CHEMICAL SPECIFICATION FOR ZINC DIE CASTING ALLOYS
Alloy No. 3 (UNS Z 33521) No. 5 (UNS Z 35530) No. 7 (UNS Z 33522)
Composition % Ingot Casting Ingot Casting Ingot Casting
Al 3.9-4.3 3.5-4.3 3.9-4.3 3.5-4.3 3.9-4.3 3.5-4.3
Mg .025.05 .020-.05 .03-.06 .03-.06 .010.-020 .005-.020
Cu .1O max .25 max 0.75-1.25 0.75-1.25 .l0 max .25 max
Ni - - - - ,005-.020 .005-.020
Fe max .075 .I00 ,075 ,100 .075 .075
Pb max .004 ,005 ,004 .005 .0020 .0030
Cd max .003 ,004 ,003 ,004 .0020 .0020
Sn max .002 ,003 ,002 ,003 .0010 .0010
Zn Remainder Remainder Remainder
Ingot Specifications Per ASTM B240-79 Casting Specifications Per ASTM B66-63
914-427-2151