After iron, aluminum, and copper, zinc is the fourth most abundant metal on the planet from Anna Daniell's blog

After iron, aluminum, and copper, zinc is the fourth most abundant metal on the planet.  When combined with the global demand for zinc, the global supply of zinc increased to 13. 4 million tonnes in 2018.  It is also estimated that secondary zinc production accounts for 20–40% of global consumption, which represents a significant amount of zinc.  The strict limitation on impurities in die-casting composition standards, on the other hand, ensuresaluminum die castings almost all zinc die-casting alloys are derived from zinc primary production. 

According to the ASTM B86 standard, the chemical compositions of the most frequently used alloys are listed in Table 1.

Addition of copper enhances the alloy's mechanical properties, such as tensile strength, hardness, and wear resistance, as well as its creep behavior.  Because of the high purity of Zn, a small amount of magnesium is usually included to help prevent intergranular corrosion.  However, this is no longer necessary in modern practice due to the high purity of Zn.
A variety of processes can be used to manufacture zinc die casting, depending on the amount of alloying elements present.  For example, hot chamber die-casting, cold chamber die-casting, gravity and sand casting, as well as spin casting and slush casting, are all possible methods of production.

A similar process, slush casting, is used for the production of hollow products, such as table lamp bases.  Pouring liquid metal into the mold and allowing aluminum die castings to solidify, resulting in the formation of a shell on the mold wall.  In the following step, the remaining liquid in the core is poured out, leaving a hollow shell with a smooth surface that is suitable for painting.  Zinc alloys with extremely high fluidity and a narrow solidification range, such as those containing 5–6% aluminum and 1% copper, are required for this casting technology.

Structures of the microenvironment 4.
In industrial applications, hypoeutectic alloys are the most commonly encountered materials because they correspond to the hot-camber die-casting alloys known as Zamak.  Because they are more devoted to cold chamber process or gravity and sand casting, the hyper-eutectic/eutectoid alloys only cover a more limited market.  So the resulting microstructures differ depending on the specific cooling rate associated with the foundry process, as well as on other factors.


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By Anna Daniell
Added Oct 20

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