Zincaluminum

Zincaluminum refers to zinc-based alloys in which aluminum is the primary alloying element. The aluminum content typically ranges from about 8 to 27 percent, depending on the grade, with small additions of elements such as magnesium or copper to tailor properties. The resulting alloys aim to combine the good castability and low density of zinc with higher strength, hardness, and wear resistance than pure zinc.

Commonly used zinc–aluminum alloys in die casting include ZA-grade alloys, such as ZA8 and ZA12, and higher-aluminum variants. These alloys are chosen for their strength, good corrosion resistance, and ability to reproduce fine details in complex shapes. Their mechanical properties depend on composition and processing, but they generally offer better strength and stiffness than pure zinc while remaining relatively easy to machine and coat.

Properties and performance: zinc–aluminum alloys exhibit improved yield strength and hardness, along with improved creep resistance and wear resistance compared with pure zinc. They maintain good corrosion resistance, though long-term performance depends on environment and alloy composition. They typically have a lower melting point than many aluminum alloys, which supports efficient casting, but may require protective coatings for outdoor or aggressive environments.

Production and applications: these alloys are produced by melting zinc and alloying with aluminum before casting, most commonly by high-pressure die casting. They are widely used for automotive components, mechanical housings, electrical and electronics enclosures, and various hardware items due to their good detail reproduction and strength-to-weight balance.

Coatings: zinc–aluminum coatings applied to steel offer enhanced corrosion resistance over traditional zinc coatings. Typical formulations include around 55% zinc and 40–45% aluminum with small amounts of silicon, marketed under coatings such as zinc–aluminum or Galvalume/Zincalume systems for roofing and exterior panels.