recent zinc casting alloy developments: technology and markets

Interna'onalZincAssocia'on

Recent Zinc Casting Alloy Developments: Technology and Markets

Frank Goodwin, Sc.D. International Zinc Association, USA

Presented by

Rob White, IZA Sub-Saharan Africa


Shanghai Tokyo

Joburg

Delhi

Lima

Moscow Brussels

Raleigh

Toronto

Melbourne

Sao Paolo

Interna'onalZincAssocia'on•  Establishedin1991•  80%ofWWzincproduc'on•  60%ofworldproduc'on•  Regionalpresence

•  ThreeCategories:o  43FullMemberso  >150AffiliateMemberso  58AssociateMembers

www.izasa.org


• 

IZAMissionTosupportandadvancezincproducts

andmarketsthroughresearch,development,technologytransferandcommunica'onof

theuniquea?ributesthatmakezincsustainableandessen'alforlife.


IZASAObjec'ves•  Growthemarketforzincandgrowthemarketsharein

compe55veindustries•  Educatethemarketwithrespecttotheop5maluseofzinc•  Buildthecustomerknowledgebaseandassistwithone-on-one

marke5ng•  Educatesalesforcesandmerchantswithrespecttotechnical

aspectsbenefi5ngzinc•  Focusonmarketdevelopmentprojects


WhyZincDie-cas'ngsifSG6.7?

•  Fast production cycles with low tool wear •  Accuracy of shape •  Easy to surface finish •  Good electromagnetic shielding •  High strength (tensile and proof), good

fatigue strength and hardness •  Thin wall capabilities


European Zinc Alloy Consumption Recovery and second crisis

6 D. Rollez, 2016 Brescia conference


European Zn Diecasting Market Sectors –past and future

automotive 27%

building 43%

electro/electric 10%

clothing 5%

toys&sports 4%

decoration 3% others

8%

European segmentation 2004 376kt

automo'v21%

building51%

electro/electric12%

clothing4%

toys&sport3%

decora'on3%

others6%

Europeansegmenta'on2050~350kt

Growth without extra effort of Development/Marketing

D. Rollez, 2016 Brescia conference


Asia Pacific Zn Diecasting Markets

L. Tao, 2016 Brescia conference


ASEAN Zinc Diecasting Market •  Dynamic Growth observed •  Overall ASEAN Market Size has increased 10~15% CAGR over past

10 years •  Thailand, Indonesia, Vietnam and Malaysia are main markets, each

has its own characteristics

L. Tao, 2016 Brescia conference


Overall Zinc Trend: Everything is

getting thinner!

Year Machine Wallthickness

Weightofthetray

1998 DAW80SDC 1.80mm 135g2006 DAW80FRC 1.20mm 93g2010 DAW80FRC 0.80mm 62g2016 DAW80FRC 0.28mm 27g2016 W80ZnRC 0.20mm 17g2016 W80ZnRC 0.15mm 14g

Frech- IZA trials with alloy Zamak 5 and the new HF alloy


Compositions of the most widely used Zn diecasting alloys

New!


HF

Alloy 5

Erhard and Schlotterbeck, 2016 Brescia conference

Ragone Fluidity Test Results for Traditional Zamak Alloy 5 and new high fluidity “HF” alloy


Erhard and Schlotterbeck, 2016 Brescia conference

(Zamak5)

(Zamak5)


Tensile Properties of As-Cast, Naturally Aged and Artificially Aged Zn Die-castings

2

3

5


HF Alloy Creep Data

0

1

2

3

4

0 400 800 1200 1600 2000

Cre

ep e

long

atio

n, %

Time, h

HF 94 MPa RT HF 68 MPa RT HF 42 MPa RT HF aa 92 MPa RT HF aa 68 MPa RT HF aa 42 MPa RT

HF as castHF artificially aged

(105°C / 72h)RT


Recent Notable Conversions to Zn Diecastings: Porsche Shift Lever

U. Schwab, 2016 Brescia Conference


Porsche Shift Lever

U. Schwab, 2016 Brescia Conference


New Application: “One Touch” Bath Water Control

Replaces Traditional Valves

•  Control of hand shower, water level and temperature

•  Optical highlight •  Easy control •  No buttons •  Bull’s eye LCD •  Current pulse (Piezo

element) through deflection of the panel

R. Seiler, 2016 Brescia Conference


“One Touch” Bath Water Control Casting Challenges

Requirements •Low wall thickness, less than 0.6mm •No deviation of flatness of the rear side (0.05mm) because of the switch resistance •Surface quality

Challenges No possibilities fill the cavity with conventional die-casting Problems to solve: •Bad spots and air pockets because of the thick edge: solidification was slower in the thick wall and enclosed the thin area •Different speeds of solidification: flow shadow •Polishing nearly impossible because of the wall thickness (press-on of polishing disc) •No deep grinding because of damaging the cast skin (Opening of micro pores or violation of tolerances) •No consistent processing possible for plating because of the bull’s eyes •No stable place for the ejectors pins •Less releasing agent because of surface requirements



Use of vacuum diecasting and other special control techniques

Conventional Diecasting

Continues improvement and mistakes led to the preferred result.



Integrated Zinc Die-casting Solution: Single Unit Grinding Station for preparing

eyeglasses lenses

Measure thickness and guide the grinding

An optician can now get a high-end machine at reasonable cost

J. Fiumana, 2016 Brescia conference


Single Unit Grinding Station for preparing eyeglasses lenses

Frame Lever Carriage

•  Easy to machine •  Dimensional stability •  Zinc die casting process precision: robustness of final assembly •  Natural damping ability of Zinc alloys: accuracy of device in use •  Zinc alloys crimping ability: to settle ball bearing on the

part

J. Fiumana, 2016 Brescia conference


KitchenAid decided to develop a new coffee machine characterized by a stunning shapes and innovative finishes. KitchenAid asked to Bruschi a solution to reach its goal. Bruschi simulated with MAGMASOFT ® the whole cover to ensure to KitchenAid a great result, innovative shapes and saving.

Upgrade from Plastic: KitchenAid Nespresso Coffee Maker

P. Rastelli, 2016 Brescia conference


KitchenAid Artisan Nespresso

Co-Design On all the parts the co-design activity has been carried out along with the customer technical team The final shape of the parts has properly designed in order to meet both functional and process requirements The DFM study included filling simulation and thermal balancing simulation by means of MagmaSoft program These activities allowed reaching the correct thickness value, considering the good structure of the casting and the good surface condition ‘’The activity of co-design is our way to support our customer in the initial phase of project or improving existing products or components’’



KitchenAid Artisan Nespresso

Saving The bigger parts met the flatness requirements within 0.3mm, even after heating in powder coating process No adjusting in assembling operation Excellent quality in powder coating finishing (single and double layer) Dimensional stability, mold duration, almost no secondary operations The vacuum system, developed entirely in Bruschi since 1985, currently installed on all the machines allows to get scrap rates close to zero

‘‘Thanks to our technology we can offer to our customers several advantages related to performances and saving ’’



Detailsthatmakethedifference



Some Zinc Diecastings in KitchenAid Nespresso Coffee Maker



NADCA Diecasting Competion 2016 1 Zinc Winner


NADCA Diecasting Competition 2016 “Teller Cash Recycler”


BruschiTechnicalManagerErmoFusèsaid:"Thesecomponentsareagreatsuccessforus.Meandmyteamworkedverycarefullyoverthecustomerneeds,fromtechnicaldesigntomassproduc<on.Wehavedevelopedmouldsthatallowedseveraladvantagesintermsofsaving,obtainingcri<calshapesdirectlybydie-cas<ng.Thechangeofmaterial,fromseveralpartsinstainlesssteeltotwopartsinzamak,allowedustomeettherequiredprecisionwhileconsiderablecostreduc5onhasbeenachieved.”


New IZA publication: Engineering in Zinc, Today’s Answer

•  20 page brochure that highlights all possibilities that you have with zinc die-castings. –  Advantages –  Characteristics of the different alloys –  Material Properties –  Engineering Characteristics –  Surface finishing options –  Casting technologies –  Benefits of hot chamber pressure die-casting –  Comprehensive tables with alloy properties and

applicable standards for chemical composition.


IZA brochures, case studies and technical data on zinc die-casting

are available at http://diecasting.zinc.org/

•  German and Italian pages are developed for the properties database

recent zinc casting alloy developments: technology and markets

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