Matching an Aluminum alloy to ZAMAC 5 properties 2

[kc2ilq]

Hi!

I'm working on a design of an aluminum component that will allow me to phase out my current ZAMAC 5 product.

I'd like to switch to Aluminum for several reasons, including the weight of the finished item, as well as the ability to anodize. However, I can not jeopardize the physical properties of my product by reducing hardness, shear strength, etc., and would like the finished product to have (almost) the same properties as its ZAMAC 5 predecessor.

The components will be die cast.

Any help in identifying the correct alloy to use is greatly appreciated.

Thanks,

Josh

 

[swall]

Your starting point should be 380 die cast aluminum, which has similar properties to Zamak 5, with the exception of shear strength. But, you first need to approach a die caster to see your part is a candidate for aluminum from a castability standpoint.One cautionary note--it is difficult to pin down die cast properties from published data, which is always in the form of "typical properties" rather than guaranteed minimums. Typical properties are derived from separately cast bars and may not be representive of the mechanical properties of the casting and you utimately may have to resort to strength testing of actual castings.

 

[kc2ilq]

Thanks so much for your helpful response.

I have already received confirmation from my factory that they are able to cast the parts in aluminum, but they were unsure of what alloy to use for the initial tests.

I will have them begin with A380.0F for testing, and we'll go from there.

Thanks again!

Josh

 

[TVP]

Josh,

Keep in mind that anodizing performance of high pressure die cast alloys in general is not good. The high Si alloys 380/383/390 have poor appearance, while the Mg-alloyed grade 518.0 has the ability to produce anodized parts with excellent cosmetic/aesthetic appeal. 518.0 is similar to 380 in terms of strength, better for elongation. The problem is that it is significantly more difficult to cast into thin sections/intricate shapes without cracking or forming other types of defects. Make sure you are working with the anodizer together with the casting company to optimize the final product performance.

 

[kc2ilq]

Thanks for another extremely helpful response!

We are making parts with very intricate shapes and thin sections (<1mm) for the consumer goods / general merchandise industry. Therefore, I do not believe that 518.0 will be suitable (solely based on the previous reply).

If I use A380, can I barrel plate the parts as I currently do with ZAMAK?

What is meant by "poor appearance" of high Si alloys?

Josh

 

[swall]

The parts will tend to have a mottled or blotchy appearance rather than a uniform finish. They will not be bright; but will tend to be dull in addition to the botchness. If cosmetics are important, you could dye the anodize, although keep in mind that it would have to be a dark tint like black or o/d.

 

[CoryPad]

What kind of plating did you have in mind?

 

[TVP]

http://www.google.com/search?hl=en&q=anodized+aluminum+die+cast+appearance