![\"zamak\"](\"https:\/\/iranmetalsmarket.ir\/en\/wp-content\/uploads\/2021\/10\/74888.jpg\")
cadmium, tin, nickel, chromium and manganese can also be observed.<\/p>\nZamak alloys are a member of the zinc-aluminum alloy family.\u00a0This alloy was first introduced to the field of metallurgical science in 1929 by the Zinc Company of New Jersey.<\/p>\n
Zamak has different grades, of which Zamak 2, Zamak 3, Zamak 5 and Zamak 7 have the most industrial use<\/span><\/strong>\u00a0.\u00a0Zamak is an acronym for the main elements of this alloy in German.<\/p>\n The element has a white color with a blue or silver sheen.\u00a0The same color, appearance and some\u00a0properties of zinc\u00a0can be seen to some extent in Zamak alloy.\u00a0This alloy is a suitable alloy for casting due to its low melting point and good fluidity.\u00a0Zamak melting temperature is about 450 degrees Celsius and its production is possible in electric and flame arc furnaces.<\/p>\n The mechanical properties of Zamak alloy are very good and the hardness of this alloy is higher than some alloys. Also, the toughness of this alloy is really impressive. So that the specimens under tensile test show high strength from high. Zamak can withstand oxidation at temperatures up to 200\u00b0 C.<\/p>\n To produce Zamak alloy, first an aluminum melt is prepared and then pieces of pure copper are thrown into the melt. It is necessary to raise the temperature so that all the copper dissolves inside the aluminum.<\/p>\n Once the AL-cu mixture is ready, it is milled. This mixture is brittle. The properties of aluminum in combination with zinc make this alloy one of the most widely used aluminum and zinc alloys and has many applications.<\/p>\n Once the ingots are completely frozen, melt the zinc in another plant.\u00a0The frozen Al-cu Amijan ingot is then thrown into the molten bush.\u00a0It is necessary for the ingot to go down and dissolve completely inside the melt.\u00a0Once the alloy melt is ready, it is cast.<\/p>\n Due to the fact that Zamak alloy has a very short freezing range, it has a high tendency to crust.\u00a0This makes compression and die casting more popular for the production of this alloy.\u00a0Feeding and freezing are usually easy to determine.<\/p>\n The specific gravity of this alloy is high.\u00a0Therefore,\u00a0it is necessary not to forget about weightlifting in compression systems<\/span>.\u00a0<\/strong>Zamak alloy is a suitable alloy for casting due to its low melting point, good fluidity and concentrated shrinkage.<\/p>\n On the main element is Zamak alloy.\u00a0The higher the amount of this element in the alloy, the higher the strength of the alloy.\u00a0Adding this element also increases the corrosion resistance of the alloy.<\/p>\n After zinc, aluminum plays a major role in Zamak.\u00a0This element increases the tensile strength, creep resistance and impact strength of the alloy.\u00a0In addition, the addition of this element increases the hardness of the alloy.\u00a0Note, however, that increasing this element by more than 5% will greatly increase the brittleness of the alloy.<\/p>\n Aluminum increases the fluidity of the alloy. So that if the amount of this element is less than 3.5%, the molten fluidity of the alloy is reduced and it must be cast at higher temperatures.<\/p>\n In any case, the amount of Zamak aluminum must be carefully controlled. Because if its value is more than 3.5 to 4.3 percent, it will negatively affect the mechanical properties of the alloy.<\/p>\n Increased tensile strength, creep, hardness and corrosion resistance are the results of adding copper to Zamak. In general, copper alloys have lower impact strength.<\/p>\n Therefore, we try to limit the amount of copper in zinc alloys under pressure (except Zamak 2) to 1.25 percent. Note that the increase in copper in this alloy also forms the brittle phase of Al2<\/sub>\u00a0Cu and in addition to reducing flexibility, will also reduce the dimensional accuracy of the cast alloy.<\/p>\n Magnesium increases the hardness of the alloy. But it reduces the impact strength, elongation percentage and fluidity of the alloy melt. It has been seen in some cases that this element is also used for deoxygenation. Magnesium increases the corrosion resistance of the alloy.<\/p>\n But even with a small amount of nickel, this goal can be achieved. However, the nickel element in the alloy forms the Ni2<\/sub>Al3<\/sub>\u00a0compound\u00a0, which will increase the hardness and brittleness of the final part by increasing the amount of molten slag.<\/p>\n Iron is generally recognized as an impurity in pressurized castings. Because the solubility of iron in zinc-aluminum alloy is low. Excess amounts of iron increase slag at the top of the melt (for example, the FeAl3<\/sub> compound accumulates at the top of the melt).<\/p>\n The iron element also increases the brittleness of cast alloys and creates problems in machining the final part.<\/p>\n These elements are known as insidious agents in the alloy composition.\u00a0Because they do not show their destructive effects at the very beginning.\u00a0The effects of the compounds of these elements usually appear over time and cause problems such as cracking and tearing in the part, especially in humid weather.<\/p>\n These elements in the melt form the compounds Mn2<\/sub>Al5<\/sub> , CrAl4<\/sub> , Ni2<\/sub>Al3<\/sub>\u00a0, which are the main compounds of molten slag.\u00a0These elements in combination with aluminum increase the slag.\u00a0According to research, these intermetallic compounds, in most cases, reduce the solubility limit.<\/p>\n In the Iranian market, Zamak is also known as dry lead, but this word is wrong.\u00a0Dry lead is an alloy of lead and antimony that has nothing to do with Zamak<\/span>.<\/strong><\/p>\n Interestingly, due to some\u00a0properties of lead and iron, they are the most dangerous elements in the composition of Zamak.<\/p>\n Because the melting point of lead is lower than Zamak and it does not dissolve at all on zinc.\u00a0In case of incomplete dissolution, it goes to the grain boundaries and accumulates in those areas, causing hot failure of the part.<\/p>\n As mentioned, Zamak alloy is often used in parts that are pressed.\u00a0Parts such as door and window components or car handles.\u00a0To better understand the use of this alloy, consider the piece “Espanolite”:<\/p>\n Espanolites are a type of fixture that is usually used in double-glazed windows, with several small tabs along the length of the profile, to lock the door or window frame to the frame.\u00a0In this way, by engaging the Zamak, the door or window sash adheres more firmly to its frame.<\/p>\n Zamak also plays an important role in regulating double-glazed doors and windows.\u00a0The made parts must be adjusted properly so that the adjustment of the double-glazed door and window is not a problem.\u00a0In addition, Zamak in double-glazed doors and windows can be repaired and replaced, and there are no restrictions.<\/p>\n In addition to these types of applications, due to the beautiful appearance of this alloy, it is also used in the manufacture of decorative parts such as toys and some jewelry and rhinestones.\u00a0This alloy is also used in mechanical, electrical and automotive industries as corrosion-resistant (galvanized) coatings.<\/p>\n One of the main applications of plating is in beautifying the surface of metals.\u00a0Due to the softness of precious metals such as gold, it can not be used in the strength parts of structures. For luxury and beauty work, gold plating is used on these parts.\u00a0This process is also widely used in making and decorating watches for beautification.<\/p>\n An example of beautification by plating is plating in car body design. Although the use of chrome in the car body is due to the use of anti-wear properties of this material, but today, chrome coating has a visual appeal among car fans, and therefore customer’s request for this coating on their car is for beauty. Other measures taken in the automotive industry to design luxury and custom cars are plating the car body with gold.<\/p>\n One of the most important reasons for using plating is to prevent chemical corrosion of materials.\u00a0Hence, this is done in two ways.\u00a0One is that the parent metal is coated with a metal that has a high resistance to corrosion, and the other method is coated with a metal that has more corrosion properties than the parent metal.<\/p>\n In the first method:<\/strong> The use of metals with low corrosion properties as a coating is like coating an iron lover with silver.<\/p>\n In the second method:<\/strong> The most common example of which is white iron ( galvanized iron ), the steel is coated with a layer of zinc that is more corrosive than steel to be corroded instead of steel in the face of corrosion.<\/p>\nCharacteristics of Zamak alloy<\/h3>\n
<\/i><\/i>How to produce Zamak alloy<\/h3>\n
<\/i><\/i>Mechanical properties of different grades ZAMAK<\/h3>\n
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\n <\/td>\n Zamak 2<\/span><\/strong><\/td>\n Zamak 3<\/span><\/strong><\/td>\n Zamak 5<\/span><\/strong><\/td>\n Zamak 7<\/span><\/strong><\/td>\n<\/tr>\n \n Ultimate tensile strength (Mpa)<\/span><\/strong><\/td>\n 397<\/td>\n 268<\/td>\n 331<\/td>\n 285<\/td>\n<\/tr>\n \n Surrender strength (Mpa)<\/span><\/strong><\/td>\n 361<\/td>\n 208<\/td>\n 295<\/td>\n 285<\/td>\n<\/tr>\n \n Percentage increase<\/span><\/strong><\/td>\n %6<\/td>\n %6.3<\/td>\n %3.6<\/td>\n %14<\/td>\n<\/tr>\n \n Shear strength (Mpa)<\/span><\/strong><\/td>\n 317<\/td>\n 214<\/td>\n 262<\/td>\n 214<\/td>\n<\/tr>\n \n Hardness (Brinell)<\/span><\/strong><\/td>\n 130<\/td>\n 97<\/td>\n 91<\/td>\n 80<\/td>\n<\/tr>\n \n Modulus of elasticity (GPa)<\/span><\/strong><\/td>\n 96<\/td>\n 96<\/td>\n 96<\/td>\n 96<\/td>\n<\/tr>\n \n Density (Kg\/dm3<\/sup>)<\/span><\/strong><\/td>\n 6.8<\/td>\n 6.7<\/td>\n 6.7<\/td>\n 6.7<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n <\/h3>\n
Zamak alloy elements (according to ASTM B 240 standard)<\/h3>\n
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\n <\/td>\n Zamak 2<\/span><\/strong><\/td>\n Zamak 3<\/span>
\n<\/strong><\/td>\nZamak 5<\/span>
\n<\/strong><\/td>\nZamak 7<\/span>
\n<\/strong><\/td>\n<\/tr>\n\n Aluminium<\/span><\/strong><\/td>\n 4.3 – 3.9
\n<\/strong><\/td>\n4.3 – 3.9<\/td>\n 4.3 – 3.9<\/td>\n 4.3 – 3.9<\/td>\n<\/tr>\n \n Copper<\/span><\/strong><\/td>\n 2.9 – 2.6<\/td>\n 0.1 – 0<\/td>\n 1.25 – 0.75<\/td>\n 0.1 – 0<\/td>\n<\/tr>\n \n Magnesium<\/span><\/strong><\/td>\n 0.05 – 0.025<\/td>\n 0.05 – 0.025<\/td>\n 0.06 – 0.03<\/td>\n 0.02 – 0.01<\/td>\n<\/tr>\n \n Lead<\/span><\/strong><\/td>\n 0.004 – 0<\/td>\n 0.004 – 0<\/td>\n 0.004 – 0<\/td>\n 0.002 – 0<\/td>\n<\/tr>\n \n Cadmium<\/span><\/strong><\/td>\n 0.003 – 0<\/td>\n 0.003 – 0<\/td>\n 0.003 – 0<\/td>\n 0.002 – 0<\/td>\n<\/tr>\n \n Tin<\/span><\/strong><\/td>\n 0.002 – 0<\/td>\n 0.002 – 0<\/td>\n 0.002 – 0<\/td>\n 0.001 – 0<\/td>\n<\/tr>\n \n Iron<\/span><\/strong><\/td>\n 0.075 – 0<\/td>\n 0.035 – 0<\/td>\n 0.075 – 0<\/td>\n 0.075 – 0<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n <\/h3>\n
<\/i><\/i>The effect of alloying elements on the properties of the alloy<\/h3>\n
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Zinc<\/h4>\n<\/li>\n<\/ul>\n
Why Zinc?<\/h5>\n
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Aluminum<\/h4>\n<\/li>\n<\/ul>\n
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Copper<\/h4>\n<\/li>\n<\/ul>\n
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Magnesium<\/h4>\n<\/li>\n<\/ul>\n
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Iron<\/h4>\n<\/li>\n<\/ul>\n
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Cadmium & Tin<\/h4>\n<\/li>\n<\/ul>\n
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Nickel & Chromium & Manganese<\/h4>\n<\/li>\n<\/ul>\n
<\/i><\/i>Is Zamak the same as dry lead?<\/h3>\n
<\/i><\/i>In what cases is Zamak used?<\/h3>\n
Reasons for using Zamak plating<\/h3>\n
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<\/span>Beautiful work<\/h4>\n<\/li>\n<\/ul>\n
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<\/span>Prevent chemical corrosion<\/h4>\n<\/li>\n<\/ul>\n