Alloy Specifications

Chemical Composition Charts

Commercial ANSI/AA Zamak Die Casting Alloys ZA Die Casting Alloys
No.3 No.5 ZA-8 ZA-12
Detailed Composition
Aluminum (Al) 3.5-4.3 3.5-4.3 8.0-8.8 10.5-11.5
Magnesium (Mg) 0.02-0.05 0.03-0.08 0.015-0.030 0.015-0.030
Copper  (Cu) 0.25 0.75-1.25 0.8-1.3 0.5-1.2
Iron (max) (Fe) 0.10 0.10 0.075 0.075
Lead (max) (Pb) 0.005 0.005 0.006 0.006
Cadmium (max) (Cd) 0.004 0.004 0.006 0.006
Tin(max) (Sn) 0.003 0.003 0.003 0.003
Nickel  (Ni) - - - -
Zinc  (Zn) Balance Balance Balance Balance

 

* Single value indicates maximum
** All values are percentage by weight

Typical Material Properties

Commercial ANSI/AA Zamak Die Casting Alloys ZA Die Casting Alloys
No.3
No.5
ZA-8
ZA-12
Mechanical Properties

Ultimate Tensile Strength

As-Cast ksi (MPa)

41(283) 48(328) 54(372) 59(400)

Yield Strength

As-Cast ksi (MPa)

32 (221) 39 (269) 41-43
(283-296)
21 (140)
Compressive Yield Strength 
As-Cast ksi (MPa)

60

(414)

87

(600)

37

(252)

39

(269)

Elongation 

As-Cast % in 2in. (51mm)

10 7 6-10 4-7
Hardness
As-Cast BHN
82 91 100-106 95-105

Shear Strength 

As-Cast ksi (MPa)

31(214) 38 (262) 40 (275) 43 (296)
Impact Strength As-Cast ft-lb 43 48 24-35 15-27

Fatigue Strength (f)  

As-Cast ksi (MPa)

6.9 (47.6) 8.2 (56.5) 15 (103) -

Young’s Modulus 

psi x 10 6 (GPa)

- - 12.4 (85.5) 12 (83)
Physical Properties

Density

lb / in³

(g/cm³)

0.24
(6.6)
0.24
(6.6)
0.227
(6.3)

0.218

(6.03)

Melting Range

°F

(°C)

718-728 (381-387)

717-727

(380-386)

707-759  (375-404)

710-810

(377-432)

Specific Heat

BTU / lb °F

(J/kg °C)

0.10
(419)
0.210
(419)
0.104
(435)
0.107  (450)

Coefficient of Thermal Expansion  

µ in / in°F

µ m / m°K

15.2
(27.4)
15.2
(27.4)
12.9
(23.2)
13.4
(24.1)

Thermal Conductivity

BTU / ft hr°F

(W / m °K)

65.3
(113)
62.9
(109)
66.3
(115)
67.1
(116)

Electrical Conductivity

µ Ω in.

27 26 27.7 28.3
Poisson’s Ration 0.30 0.30 0.30 0.30

 

Commercial  ANSI/AA Zamak Die Casting Alloys
No.3 No.5 ZA-8 ZA-12
Resistance to Hot Cracking (a) 1 2 2 3
Pressure Tightness 1 2 3 3
Casting Ease 1 1 2 3
Part Complexity 1 1 2 3
Dimensional Accuracy 2 2 2 3
Dimensional Stability 3 3 2 2
Corrosion Resistance 2 4 5 2
Resistance to Cold Defects (b) 2 2 2 3
Machining Easy & Quality (c) 1 1 2 3
Polishing Ease & Quality 1 1 2 3
Electroplating Ease & Quality (d) 1 1 1 2
Anodizing (Protection) 1 1 1 2
Chemical Coating (Protection) 1 1 2 3

 

(a) The ability of alloy to resist formation of cold defects; for example, cold shuts, cold cracks, non-fill “woody”areas, swirls, etc.
(b) Ability of alloy to withstand stresses from contraction while cooling through the hot-short or brittle temperature range.
(c) Composite rating based on ease of cutting, chip characteristics, quality of finish, and tool life.
(d) Ability of the die casting to take and hold an electroplate applied by present standard methods.
 

1= Most Desirable

5 = Least Desirable

Chemical Composition Charts

Detailed Composition Aluminum Die Casting Alloys
360 380 384 413
Silicon (Si) 9.0-10.0 7.5-9.5 10.5-12 11.0-13.0
Iron (Fe) 2.0 2.0 1.3 2.0
Copper (Cu) 0.6 3.0-4.0 3.0-4.5 1.0
Magnesium (Mg) 0.4-0.6 0.10 0.10 0.10
Manganese (Mn) 0.35 0.50 0.50 0.35
Nickel (Ni) 0.50 0.50 0.50 0.50
Zinc (Zn) 0.50 3.0 3.0 0.50
Tin (Sn) 0.15 0.35 0.35 0.15
Total Others   0.25 0.50 0.50 0.25
Aluminum (Al) Balance Balance Balance Balance

* Single value indicates maximum

** All values are percentage by weight 

Typical Material Properties

Mechanical Properties Aluminum Die Casting Alloys
360 380 384 413
 
Ultimate Tensile Strength ksi (MPa) 44 (303) 46 (317) 48 (330) 43 (300)

Yield Strength

ksi (MPa)

25 (170) 23 (160) 24 (165) 21 (140)

Elongation 

% in 2in. (51mm)

2.5 3.5 2.5 2.5

Hardness

BHN

75 80 85 80

Shear Strength 

ksi (MPa)

28 (190) 28 (190) 29(200) 25 (170)

Impact Strength

ft-lb

- - 3 (4) -
Fatigue Strength ksi (MPa) 20 (140) 20 (140) 20 (140) 19 (130)

Young’s Modulus  

psi x 10 6(GPa)

10.3  (71) 10.3  (71) - 10.3  (71)
Physical Properties

Density

lb / in³(g/cm³)

0.095
(2.63)

    0.099

(2.74)

0.102
(2.82)
0.096
(2.66)

Melting Range

°F

(°C)

1035-1105 (557-596) 1000-1100 (540-595) 960-1080 (516-582) 1065-1080 (574-582)

Specific Heat

BTU / lb °F

(J/kg °C)

0.23
(963)
0.23
(963)
0.23
(963)
0.23
(963)

Coefficient of Thermal Expansion 

µ in / in°F

µ m / m°K

11.6
(21.0)
12.2 
(22.0)
11.6
(21.0)
11.3
(20.4)

Thermal Conductivity BTU / ft hr°F

(W / m °K)

65.3
(113)
55.6
(96.2)
55.6
(96.2)
70.1
(121)

Electrical Conductivity

% IACS

30 27 22 31
Poisson’s Ration 0.33 0.33 - -

 

 

Die Casting and Other Characteristics: Al Alloys

  Aluminum Die Casting Alloys
360 380 384 413
Resistance to Hot Cracking (a) 1 2 2 1
Pressure Tightness 2 2 2 1
Die-Filling Capacity (b) 3 2 1 1
Anti-Soldering to the Die (c) 2 1 2 1
Corrosion Resistance (d) 2 4 5 2
Machining Easy & Quality (e) 3 3 3 4
Polishing Ease & Quality (f) 3 3 3 5
Electroplating Ease & Quality (g) 2 1 2 3
Anodizing (Appearance) (h) 3 3 4 5
Chemical Oxide Protective Coating (i) 3 4 5 3
Strength at Elevated Temp. (j) 1 3 2 3

 

(a) Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature ranges.
(b) Ability of molten alloy to flow readily in die and fill thin sections.
(c) Ability of molten alloy to flow without sticking to the die surfaces. Ratings given for anti-soldering are based on nominal iron compositions of approximately 1%.
(d) Based on resistance of alloy in standard type slat spray test.
(e) Composite rating based on ease of cutting, chip characteristics, quality of finish, and tool life.
(f) Composite rating based on ease and speed of polishing and quality of finish provided by typical polishing procedure.
(g) Ability of the die casting to take and hold an electroplate applied by present standard.
(h) Rated on lightness of color, brightness, and uniformity of clear anodized coating applied in sulphuric acid electrolyte.
(i) Rated on combined resistance of coating and prolonged heating at testing temperature.

1= Most Desirable

5 = Least Desirable

360 - Selected for best corrosion resistance. Special alloys for special applications are available, but their use usually entails significant cost premiums.

380 - An alloy which provides the best combination of utility and cost. Approximately 95% of aluminum die castings are produced from 380 Aluminum.

383 & 384 - These alloys are a modification of 380. Both provide better die filling, but with a moderate sacrifice in mechanical properties, such as toughness.

413 (A13) - Used for maximum pressure tightness and fluidity.

Performance - Martyr I & Martyr II Anodes

 

SPECIFICATIONS

MARTYR I 
ZINC ANODES

MARTYR II 
ALUMINUM ANODES

CAPACITY, ampere-hours per pound

355

1225

EFFICIENCY (test)

95%

94%

CONSUMPTION, pound per ampere-year

24.5lbs

7.6lbs

POTENTIAL (reference Cu/CuSO4

-1050mV

-1100mV

Composition - Martyr I & Martyr II Anodes
 

COMPOSITION

U.S. Military Specification*
MIL-DTL-18001L 
Martyr I  Zinc Alloy

U.S. Military Specification*
and MIL-DTL-24779C
Martyr II Aluminum Alloy

Cadmium

0.025% - 0.07%

-

Copper

0.005% Max.

0.004% Max.

Iron

0.005% Max.

0.090% Max.

Indium

-

0.014% - 0.020%

Lead

0.006% Max.

-

Mercury

-

0.001% Max.

Silicon

-

0.08% - 0.20%

Aluminum

0.1% - 0.5%

Remainder

Zinc**

Remainder

4.0% - 6.5%

Comparison between Martyr I & Martyr II Anodes
 

Martyr I (Zinc Anodes)

 

Martyr II (Aluminum Anodes)

355 Ampere hours per pound   1225 Ampere hours per pound
This means a Zinc anode will give one amp for 355 hours  for every pound of Zinc   This means an Aluminum anode will give one amp for 1225 hours for every pound of Aluminum
Take a typical Z3 (weight=4.68 kg) 
Total ampere hours 3656
  Take a typical AZ3 (weight = 2.7 kg)
Total ampere hours 6125
Assuming the anode performs at 0.5 amp   Assuming the anode performs at 0.5 amp
This anode will last for 7312 hours   This anode will last for 12250 hours
Which is 304 days   Which is 510 days
Which is 10 months   Which is 16.5 months

 

Performance - Martyr I & Martyr II Anodes

 

SPECIFICATIONS MARTYR I
ZINC ANODES
MARTYR II
ALUMINUM ANODES
CAPACITY, ampere-hours per pound 355 1225
EFFICIENCY (test) 95% 94%
CONSUMPTION, pound per ampere-year 24.5lbs 7.6lbs
POTENTIAL (reference Cu/Cu SO4) -1050mV -1100mV

 

 

Composition - Martyr I & Martyr II Anodes

 

COMPOSITION

U.S. Military Specification*

MIL-DTL-18001KL

Martyr I  Zinc Alloy

U.S. Military Specification*

MIL-DTL-24779C

Martyr II
Aluminum Alloy

Cadmium 0.025% - 0.07% -
Copper 0.005% Max. 0.005% Max.
Iron 0.005% Max. 0.080% Max.
Indium - 0.015% - 0.020%
Lead 0.006% Max. -
Mercury - 0.001% Max.
Silicon - 0.08% Max
Aluminum 0.1% - 0.5% Remainder
Tin   0.001% Max
Others   0.10% Max total (0.020% max. each)
Zinc** Remainder 4.0% - 6.5%

 

 

Comparison between Martyr I & Martyr II Anodes

 

Martyr I (Zinc Anodes)

 

Martyr II (Aluminum Anodes)

 

355 Ampere hours per pound 1225 Ampere hours per pound
This means a Zinc anode will give one amp for 355 hours  for every pound of Zinc This means an Aluminum anode will give one amp for 1225 hours for every pound of Aluminum
Take a typical Z3 (weight=4.68 kg) Take a typical AZ3 (weight = 2.7 kg)
Total ampere hours 3656 Total ampere hours 6125
Assuming the anode performs at 0.5 amp Assuming the anode performs at 0.5 amp
This anode will last for 7312 hours This anode will last for 12250 hours
Which is 304 daysWhich is 10 months Which is 510 daysWhich is 16.5 months