Die-cast aluminum-zinc alloy
Die-cast aluminum-zinc alloy is a die-cast material composed primarily of aluminum and zinc, supplemented by small amounts of other alloying elements (such as copper and magnesium). Its performance lies between that of aluminum and zinc alloys, giving it unique applications in industrial production. The density of aluminum-zinc alloy is typically between 5.0-5.5 g/cm³, higher than pure aluminum but lower than zinc alloy. This density makes it advantageous in the manufacture of components that require a certain heft but are not excessively heavy. The addition of zinc not only increases the alloy’s strength and hardness but also improves its casting properties, enabling the die-casting process to produce complex parts. The resulting castings have a smooth surface and high dimensional accuracy, meeting application requirements without extensive post-processing.
In terms of mechanical properties, die-cast aluminum-zinc alloys have high strength and hardness. Their tensile strength is generally between 250-350 MPa, and their hardness can reach 80-100 HB, which is much higher than that of ordinary zinc alloys and close to the level of some aluminum alloys. At the same time, aluminum-zinc alloys also have good wear resistance and impact resistance, which makes them excellent in the manufacture of parts that are subject to friction and impact. In the field of mechanical manufacturing, die-cast aluminum-zinc alloys are often used to produce transmission components such as gears, bearings, and sliders. These components need to withstand certain loads and friction during operation. The wear resistance and strength of aluminum-zinc alloys can ensure their long-term stable operation and extend their service life. For example, after the transmission gears of a certain model of machine tool were manufactured using die-cast aluminum-zinc alloys, their service life was increased by 30% compared to traditional cast iron gears, and the operating noise was significantly reduced.
The excellent casting properties of die-cast aluminum-zinc alloys are one of the key reasons for their widespread application. The alloy’s low melting point, typically between 500-550°C, is lower than the die-casting temperature of aluminum alloys. This not only reduces thermal shock to the mold, extending mold life, but also reduces energy consumption. Furthermore, the aluminum-zinc alloy’s excellent fluidity allows it to quickly fill the mold cavity during the die-casting process, enabling even parts with fine lines and complex structures to be clearly formed. Furthermore, the aluminum-zinc alloy’s shrinkage is small and stable, generally between 0.5% and 0.8%. This helps ensure the dimensional accuracy of the casting and reduces defects such as deformation and cracking caused by uneven shrinkage. However, aluminum-zinc alloys are prone to oxidation at high temperatures. Therefore, temperature control and protective measures must be taken during the smelting and die-casting processes to prevent oxidation inclusions from affecting the quality of the casting.
Die-cast aluminum-zinc alloys are also widely used in hardware and decoration. Due to their high surface quality and ease of electroplating, painting, and other surface treatments, they create aesthetically pleasing finishes. They are often used in the manufacture of products such as door locks, handles, and lighting accessories. For example, high-end interior door lock handles are made of die-cast aluminum-zinc alloy. After chrome plating, they achieve a mirror-like finish. These handles not only offer decorative appeal but also possess high strength and wear resistance, allowing them to withstand frequent use without damage. Compared to pure zinc alloys, aluminum-zinc alloys offer lower costs and superior performance. They also offer a price advantage over copper alloys, making them highly competitive in the mid- to high-end hardware market.
With the continuous advancement of industrial technology, the performance of die-cast aluminum-zinc alloys is constantly being optimized. By adjusting the ratio of aluminum to zinc and adding other alloying elements, researchers have developed a series of aluminum-zinc alloys with specialized properties, such as highly corrosion-resistant aluminum-zinc alloys and high-temperature stable aluminum-zinc alloys, to meet the needs of various applications. In the automotive parts sector, new aluminum-zinc alloys are used to manufacture small engine peripheral components such as oil pump housings and throttle bodies, leveraging their excellent sealing and oil resistance to ensure proper engine operation. In the medical device sector, specially treated aluminum-zinc alloys can be used to manufacture the housings and connectors of some medical devices. Their non-toxic and corrosion-resistant properties meet the hygienic requirements of medical environments. In the future, with the continuous advancement of die-casting technology and the diversification of market demand, the application prospects of die-cast aluminum-zinc alloys will expand, and their unique advantages will be utilized in more fields.
