ALUMINUM DIE CASTING VS. ZINC DIE CASTING:
THE BENEFITS AND USES OF EACH

As a global leader in manufacturing for die casting, PHB pours vast quantities of aluminum and zinc every year. We are a global aluminum die casting manufacturer that does it all, serving clients ranging from automobile manufacturers to the U.S. military and beyond. PHB is also one of the world’s leading zinc die casting manufacturers, with those clients ranging from large appliance manufacturing companies to the automotive industry. While these two alloys are both commonly used for die casting, they each contain separate properties that make them a better fit for certain uses or products. Here, we will observe the benefits applicable to each alloy.

BENEFITS AND USES OF ZINC DIE CASTING

 

Zinc alloys are best known for their high ductility, impact strength, and their ability to be easily plated or finished. They also have a lower melting point than aluminum, which can assist in promoting longer die life. Due to these benefits, less material is often needed than would be if working with other alloys, leading customers to save both time and money on their project. When it comes to zinc die-cast manufacturing, PHB handles all aspects of the process, starting with mold design and testing and continuing with zinc component manufacturing, finishing, and packaging.

While often used in industrial spaces and building, one of the most common applications of zinc alloys is to produce automobile parts. Some automobile parts zinc is typically used for include (but are not limited to):

  • Interior aesthetic parts
  • Engine and other “under-the-hood” components
  • Power steering systems
  • Brake parts and systems
  • Air-conditioning components and systems
  • Fuel systems
  • Complex net-shaped housings
  • Electronic devices

Interestingly enough, due to the number of part production it requires, the automotive industry was at least partially responsible for the die casting process to begin with.

BENEFITS & USES OF ALUMINUM DIE CASTING

 

On the other hand, aluminum die casting alloys are lightweight and possess high dimensional stability that works particularly well for complex part geometries (including thin walls). Aluminum alloys have strong corrosion resistance and mechanical properties as well as high thermal and electrical conductivity, making them a great alloy for die casting. It is common to see aluminum alloys used in a wide variety of applications, including:

  • Electronics
  • Communications equipment
  • Gear cases
  • Lawnmower housings
  • Hand and power tools
  • Some automotive components

While zinc alloys are easier to plate or finish, aluminum die-cast parts have more surface finishing options and can withstand higher operating temperatures than other non-ferrous materials. Just as we do with zinc die casting, PHB handles all aspects of aluminum die-cast manufacturing, from mold design and testing to precision aluminum parts manufacturing, finishing, and packaging.

PHB IS A ZINC DIE CASTING & ALUMINUM DIE CASTING MANUFACTURER

 

PHB Inc. is a U.S.-based company and full-service manufacturer of quality products in the aluminum die casting, zinc die casting, and tool & die industries. To recap, zinc is thermally conductive, electrically conductive, exceptionally corrosion-resistant, accurate and stable with high dimensions, able to cold form, and fully recyclable.

Because of these benefits, zinc alloys are commonly used to manufacture complex metal components that require a high degree of strength and accuracy, including pieces with thin walls that may not be possible to produce with other alloys. Meanwhile, aluminum is used to produce accurate, well-defined, smooth, and textured-surfaced metal parts due to it being lightweight and durable, highly corrosion-resistant, highly conductive, relatively cost-effective, fully recyclable, and more efficient when producing a high volume of parts very quickly. Deciding which alloy is best suited for an application is usually based on the design specifications, and our team is happy to discuss the physical and mechanical properties necessary for your end product’s application.

PHB serves manufacturing companies and OEMs that demand the highest level of quality. From automotive to appliances, regardless of your industry or product, PHB has the expertise to choose the best alloy for your die-cast product. As an ITAR registered, IATF certified die casting company, we are also able to complete projects for government and military work. PHB solves active die casting problems by specializing in turning complex design specifications into a reality for our customers.

Aluminum and Zinc alloy’s commonly run at PHB Die Casting
Alloy PRO’s CON’s
A360
  • High corrosion resistance.
  • Superior strengthat elevated temperatures.
  • More difficult to cast:
    • Reduced die filling capability.
    • More prone to die soldering.
A380
  • The most widely used of the Aluminum die casting alloys.
  • Lowest cost of the Aluminum die casting alloys.
  • Best combination of material properties.
  • Poor corrosion resistance.
  • Average material properties – not particularly good or bad at anything.
383
  • 2% more silicon than A380.
  • Alternative to A380 for parts withthin walls and fine details.
  • Improved resistance to hot cracking.
  • Slightly worse than A380 for die soldering.
  • A few cents more expensive than A380.
A413
  • Excellent pressure tightness.
  • Good die filling capability.
  • Grainy surface appearance is less appealing cosmetically.
Zamak #3
  • The most widely used zinc die casting alloy in NorthAmerica.
  • The best combination of mechanical properties, castability, and economics of the Zinc alloys.
  • Can produce castings withintricate detail.
  • Excellent surface finish for plating or painting.
  • Problems withdimensional stability due to creep.
  • Very heavy compared to Aluminum.
ZA alloys
vs.
Zamak #3
  • Higher strength.
  • Superior wear resistance.
  • Superior creep resistance.
  • Lower weight.
  • More expensive.
  • Reduced die filling capability.
  • More prone to cracking.
  • Not as good for cosmetic applications.
ZA-8
  • Can run in a hot chamber die casting machine.
  • Highest strengthof any hot chamber zinc alloy.
  • Good for chrome plating applications.
Other than strength, it has no advantages over Zamak #3.
ZA-12
  • Material properties mid-way between ZA-8 and ZA-27: not particularly good or bad at anything.
  • Cold chamber only.
ZA-27
  • Highest melting point, highest strength, and the lowest density of the ZA alloys.
  • Cold chamber only.
  • Problems withresistance to cracking.
  • More difficult to machine.
Chemical Composition
Alloy Silicon
Si
Iron
Fe
Copper
Cu
Magnesium
Mg
Manganese
Mn
Nickel
Ni
Tin
Sn
Titanium
Ti
Others
Pb-Cd-Hg
Aluminum
Al
Zinc
Zn
A360 9.0-10.0 1.3 0.6 0.4-0.6 0.35 0.50 0.15 0.25 Balance 0.50
A380 7.5-9.5 1.3 3.0-4.0 0.30 0.50 0.50 0.35 0.50 Balance 3.0
383 9.5-11.5 1.3 2.0-3.0 0.10 0.50 0.30 0.15 0.50 Balance 3.0
A413 11.0-13.0 1.3 1.0 0.10 0.35 0.50 0.15 0.25 Balance 0.50
Zamak #3 0.05 0.1 max 0.02-0.06 .002 max 0.009 max 3.7-4.3 Balance
ZA-8 0.075 0.8-1.3 0.01-0.03 0.003 max 0.012 max 8.0-8.8 Balance
ZA-12 0.075 0.5-1.2 0.01-0.03 0.003 max 0.012 max 10.5-11.5 Balance
ZA-27 0.075 2.0-2.5 0.01-0.02 0.003 max 0.012 max 25.0-28.0 Balance
Casting Characteristics
Alloy Resistance to Hot Cracking Pressure Tightness Die Filling Capability Anti-Soldering to the Die Corrosion Resistance Machining Ease Polishing Ease Electroplating Ease Anodizing Appearance Chemical Coating Protection Strength at Elevated Temp.
A360 1 2 3 2 2 3 3 2 3 3 1
A380 2 2 2 1 4 3 3 1 3 4 3
383 1 2 1 2 3 2 3 1 3 4 2
A413 1 1 1 1 2 4 5 3 5 3 3
Zamak #3 1 1 1 3 1 1 1 1
ZA-8 2 3 2 2 2 2 1 2
ZA-12 3 3 3 2 3 3 2 3
ZA-27 4 4 3 1 4 4 3 3

( 1 = Most desirable, 5 = Least desirable )

 

Alloy Density and Mold Shrinkage Factor
Alloy Hot or Cold Chamber Density, Liquid (lbs./in.3) Density, Solid (lbs./in.3) Shrinkage Factor (inch/inch) #
A360 Cold .088 .095 .005
A380 Cold .093 .098 .005
383 Cold .093 .099 .005
A413 Cold .088 .096 .005
Zamak #3 Hot .221 .240 .006
ZA-8 Hot .227 .007
ZA-12 Cold .207 .218 .0075
ZA-27 Cold .172 .181 .008

Note: Shrinkage factors represent average values. Adjust the shrinkage factor according to the specific casting geometry.
(Thick wall castings will shrink more than thin wall castings)

 

Cross Reference of Alloy Designations
Common
Commercial
Name
ASTM OLD UNS SAE JAPAN JIS H 5302 GERMAN DIN 1725 ISO EN CHINA
A360 SG100A A13600 309 ADC3 233 AlSi10Mg AC-43400 YL104
A380 SC84A A13800 306 ADC10 226A AlSi8Cu3Fe AC-46500 YL112
383 SC102A A03830 383 ADC12 226A AC-46100 YL113
A413 S12A A14130 305 ADC1 231D AlSi12CuFe AC-47100 YL108
Zamak #3 AG40A Z33525 903 ZDC2 1743 ZP0400 ZnAl4 ZX01
ZA-8 ZA8 Z35638 ZP0810 ZnAl8Cu1
ZA-12 ZA12 Z35633 ZP1110 ZnAl11Cu1
ZA-27 ZA27 Z35841 ZP2720 ZnAl27Cu2

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