23. - 25. 5.

2012, Brno, Czech Republic, EU

METHODOLOGY FOR DETERMINATION THE COEFFICIENT OF THERMAL
SHRINKAGE ZINC ALLOYS
Ji MACHUTA, Iva NOV

Technical university of Liberec, Studentsk 1402/2, 461 17 Liberec 1, jiri.machuta@tul.cz, iva.nova@tul.cz
Abstract
In today's casting production is necessary at the casting production to ensure not only their quality (accuracy,
geometry, surface roughness, structure homogeneity, minimal internal stress, etc.), but also to supress of
their dimensional linear and volume changes.The article deals with measurements of linear changes of
castings from Zn-alloys during their solidification. For this purpose the measuring apparatus, which applies a
dilatometer of Polish provenience, was built up. Dilatation curves of Zn-alloys were acquired during the
casting process. The course of volume changes of castings defines the casting material ability to equalize
the loss of volume during solidification in an effective way. The volume changes at the process of graphite
cast iron solidification have been observing for a long period at our department and recently our department
of Engineering Technology at the Technical University of Liberec has been concerned with this issue Zn
alloys. At present we are carrying out experiments with Zn alloys. Zinc is blue-white metal that crystallizes in
hexagonal system. The crystal structure has the influence on his properties anisotropy (for example heat
conductivity, heat dilatation, tensile resistance, etc.). Alloys ZnAl4 (SN 42 3558), ZnAl4Cu1 (SN 42 3560)
and ZnAl4Cu3 (SN 42 3562) are the best used zinc alloys for pressure die casting. In this contribution we
would like to get acquainted professional technical public with our research results of determination Zn-alloys
coefficient thermal shrinkage.
Keywords: solidification, dimensional changes, Zn alloys, coefficient of thermal shrinkage .
1. INTRODUCTION
[2,3,4]
Foundry production focused on the production of castings with the required accuracy and surface quality
while saving energy and raw materials. Used for this purpose are especially non-ferrous materials. Besides
aluminum alloys have an important task for casting production also zinc alloys.The increasing application of
zinc alloys is related to their specific properties. The favorable technological properties of zinc alloys
contributes relatively low melting temperature (about 420C) and good casting properties. The zinc alloys
can be made small rugged castings with high dimensional accuracy and surface quality to the weight of 1 kg.
These castings are designed especially for the automotive, electronics and consumer industry
(manufacturing accessories for windows and doors). At the forefront in the production of castings from zinc
alloy is USA, followed by China, as well as Mexico, Italy, Germany, Japan, France and Great Britain.
It is necessary at the casting production to ensure not only their quality (accuracy, geometry, surface
roughness, structure homogeneity, minimal internal stress, etc.), but also to supress of their dimensional
linear and volume changes. In the case of casting alloys it is necessary to observe the linear and volume
changes especially during solidification of Zn-Al alloys, where the eutectic phase crystallization is important.
The curves of volume changes of castings defines the casting material ability to equalize the loss of volume
during solidification in an effective way. The volume changes at the process of graphite cast iron
solidification have been observing for a long period HOEK [6] and recently our Department of Engineering
Technology at the Technical University of Liberec has been concerned with this issue. At present we are
carrying out experiments with Zn alloys. In this contribution we would like to get acquainted professional
technical public with our research results.
23. - 25. 5. 2012, Brno, Czech Republic, EU


Zinc alloys that are used in our foundries have been described in detail PTEK and USTOHAL [1].
Currently appearing in the world other zinc alloys. The basis of almost all the zinc alloy used is a system of
Zn-Al. Equilibrium diagram of Zn-Al, resp. Al-Zn, see Figure 1, is a type of equilibrium diagram of an initial
phase with limited solubility additive element and the emergence of eutectic. Eutektikum phase consists of
Zn and ZnAl. Eutectic temperature is about 380C at 95% Zn content. Both metals are completely soluble
liquid. In the solid state is their limited solubility, but in aluminum dissolves a considerable amount of zinc
(about 30% at the eutectic temperature of 380C). Solubility of aluminum in zinc is very small (1% at eutectic
temperature), at normal temperature is only 0.05%.

Fig. 1 The equilibrium diagram of Al Zn [5]
Marking of zinc alloys are different from manufacturer to manufacturer and country of origin. Zinc alloys can
be divided by the amount of aluminum: a) zinc alloys with lower aluminum content; b) zinc alloys with higher
aluminum content; c) special alloy. Zinc alloys with lower aluminum content, were previously used in our
foundry under the name CSN. This three corresponding alloys used ZnAl4, ZnAl4Cu1, ZnAl4Cu3 where the
label out the contents of used additive elements (aluminum and copper). In the world of these alloys are
equivalent alloys, which are known under the trade name Zamak. (the German name of the basic elements -
Zinc, Aluminium, Magnesium, Kupfer). Fig.2 show Zn - Al - Cu ternary system showing the chemical
composition of selected zinc alloys Zamak alloys correspond to the next, the world equivalent designation
used zinc alloys: Zamak 3 - ZnAl4 - Zn400 - ZL3 - ZL0400, CSN 423558; Zamak 5 - ZnAl4Cu1 - Zn410 - ZL5
- ZL0410, CSN 423660; Zamak 2 - ZnAl4Cu3 - Zn430 - ZL52 - ZL0430, CSN 423562 (CSN indicates Czech
standard).

Fig. 2 Zn - Al - Cu ternary system showing the chemical composition of selected zinc alloys [7]
23. - 25. 5. 2012, Brno, Czech Republic, EU


Casting properties of these three alloys are similar, the only difference between them is the copper content.
Copper, like aluminum, reduces the grain size increases the mechanical properties of alloys, especially
tensile strength, elongation and impact resistance and improves running quality alloys. When the copper
content of 0.7% improves corrosion resistance. The copper content alloys is in the range from 0.5 to 3%.
Magnesium content is 0.01 to 0.03%. Impurities in zinc alloys are particularly iron, lead, cadmium and tin.
Support the creation of intergranular corrosion and their content must not exceed the order of thousandths of
a percent. For this reason, the alloys must be based on very pure zinc (99.995%).Zinc alloys with higher
aluminum content, these alloys have been used here, are conducted under the name of ZA and they also
correspond to other equivalent alloys: ZA 8 - ZnAl8Cu1-ZL8 - ZL0810, ZA 12 - ZnAl12Cu1-ZL12-ZL01110,
ZA 27 - ZnAl27Cu2 - ZL27 - ZL02720. These alloys with higher aluminum content are radically different from
standard zinc alloys in the composition, properties and castability. Castings of alloys have high strength (up
to 400 MPa) and hardness (120 HBN), good machinability and wear resistance, often better than the
standard bronze alloys.
2. EXPERIMENTAL MONITORING OF THERMAL SHRINKAGE CASTING ALLOYS
The molten metal has considerably greater volume than the solidified casting. There are three quite different
contractions to be dealt with, when molten metal is cooling from the liquid state to room temperatures. As the
temperature reduces, the first contraction to be experienced is that in the liquid state. This is the normal
thermal contraction and volume of the liquid metal reduces almost exactly linearly with falling temperature. In
the case of casting the shrinkage of the liquid metal is usually not troublesome, the extra liquid metal
required to compensate for this small reduction in volume is easily provided. The phase of contraction is
quite another case, however. This contraction occurs at the freezing point, because, in general, solid has
greater density as compared to the liquid. The contraction causes several problems. These include
requirement for feeding, that is defined here as a process for compensation of solidification contraction. Solid
contraction is a very important process for production of the pattern. Contractions of the casting from its
freezing temperature to room temperature are dependent on the castings methods. There is no considerable
refilling of the molten metal loss during solidification in the case of Al-Si-alloys. The way of casting
solidification, reflections of its internal pressure ratios and external volume changes are enabled to observe
with the help of dilatation measuring.
A special measuring apparatus, as showed on Fig.3, has made-up at our department (Department of
Engineering Technology, Technical university of Liberec, Czech Republic) for the casting alloys dilatations
measuring. It consists of a movable frame with the specified cavity casting mould. The casting has shape of
I profile as shown on Fig. 4. This method of experimental crack susceptibility monitoring was elaborated
according to device of Bocvar and Svidersky that was constructed previously in our department. This old
device was now equipped with a dilatometer and a computer and thus enables adjusting of definite power
that effects rising of stoppage shrinking of solidifycated casting that may cause its damaging. This device
also enables monitoring of linear shrinkage time dependence of the experimental casting during its cooling
phase. Moulds cavity of casting sample is open and it consist of three parts metal plate, sand part 108 mm
long with middle part of casting and moving part. Experimental sample has middle part with diameter 25 x
11 mm. Sand part enables its heating while metal end parts enable its cooling. Therefore the sample
solidifies in its middle part at last. Moveable part of device is joined with inductive sensor of dilatation. This
signal is digitized and displayed on PC.
23. - 25. 5. 2012, Brno, Czech Republic, EU



Fig. 3 Scheme of the contraction measuring device

The measurements of dilatations Zn alloys and Al-alloys were carried out on this measuring device.
Measurements were carried out in moulds. Middle part of this mould was made from bentonite mixture
homogeneous forming and ends of mould were made from steel. For experimental casting were used Zn
alloys ZnAl4Cu1, ZnAl11Cu1 with casting temperatures in range of 450 C and 550 C and pure Al with
casting temperature 720 C. The experiments were monitored with measuring device showed on Fig. 4. For
temperature measuring in the heat axis of the casting, the thermocouple NiCr-Ni with conductor diameter 0.2
mm was used. It was protected by a corundum two-capillary LUXAL. It enables to find out time
dependencies of temperatures in the heat axis of the casting and also it enables to measure time
dependence of solid casting contraction on the time. Figures 5, 6 and 7 shows the dependence of linear
contraction and temperatures of Al and Zn alloys castings at time.





1 - bolster; 2 - metal plate; 3 casting cavity; 4 - sand mixture cavity; 5 - moving shaped metal plate; 6 - compressive; 7 - nut;
8 measuring detection of dilatation
Fig. 4 Scheme of measurement device with cavity
23. - 25. 5. 2012, Brno, Czech Republic, EU


0
100
200
300
400
500
600
700
800
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
as(s)
t
e
p
l
o
t
a

(

C
)
-2
-1,5
-1
-0,5
0
0,5
d
i
l
a
t
a
c
e

(
m
m
)
teplota
dilatace

Fig. 5 Time dependence of temperatures and dilatation of the castings from pure Al using mould for 720 C

Fig. 6 Time dependence of temperatures and dilatation of the castings from ZnAl4Cu1 for 450C

Fig. 7 Time dependence of temperatures and dilatation of the castings from ZnAl11Cu1 for 450C
23. - 25. 5. 2012, Brno, Czech Republic, EU


From the curve dependence expansion on the temperature is possible calculated coefficient of thermal
contraction (expansion) for Al and Zn alloys, Tab. 1. Shows examples of calculated coefficient of thermal
contraction . It was used equation:
) (
1 2
T T l
l
O

[K
-1
] (1)
Where indicates: l shrinkage of the casting [mm], l0 - original length of casting [mm], (T2-T1) -
difference of temperature [C].
Table 1 Examples of calculated coefficient of thermal shrinkage

Temperature [C]
.10-6 [K-1] Alloys
Al Zn ZnAl4 ZnAl4Cu1 ZnAl4Cu3
400 to 350 14,9 20,0 19,8 19,7 19,8
350 to 300 14,9 19,8 19,6 19,7 19,6
300 to 250 14,7 19,7 19,3 19,6 19,5

3. CONCLUSION
The paper present possibility of exact assessment of the dilatations dependences at the solidification
process of Zn alloys. Decisive parameters of experiment are influenced with the metallic charge composition,
the degree of melt overheating, chemical composition of Zn and Al alloys the method of casting cooling and
the type of the mould. From the curves and recorded dates dependence expansion on the temperature is
possible calculated coefficient of thermal contraction (expansion) for Al or Zn alloys. For experimental
casting were used Zn alloys ZnAl4Cu1, ZnAl11Cu1 with casting temperatures in range of 450 C and 550 C
and pure Al with casting temperature 720C. The experiments were monitored with measuring device
constructed at Technical university of Liberec, Department of Technology. The increasing application of zinc
alloys is related to their specific properties. The favorable technological properties of zinc alloys contribute
relatively low melting temperature (about 420C) and good casting properties.

The article was prepared with support project SGS- TUL-FS - 2822
LITERATURE
[1] PTEK, L., USTOHAL, V.: Slitiny zinku pro odlitky. Slvrenstv XLIX, 2001, . 4. 203 208.
[2] GEDEONOV, Z. et al.: Dlkov zmeny pri tuhnut grafitickch liatin a vsledn kvalita odliatku. Slvrenstv
XLIX (2001) . 9, s. 513-523. ISSN 0037-6825. (in Czech).
[3] LIPISKI, T.: Temperature at the and of phase crystallization after modification by exothermically mixture and
structure. PAN Katovwice Poland year 2004, Volume 4, NO 14, p. 267 to 272. PL ISSN 1642-5308.
[4] ZHU, Y. H., LEE, W. B., TO, S.: Ageing characteristics of cast Zn-Al based alloy (ZnAl4Cu3) Journal of
Materials Science 38 (2003). p. 1945-1952.
[5] MURPHY, S.: Metallkd, 1980 p. 96-102
[6] KRSLOV, S.: Monitoring of foundry properties of the Zinc alloys for casts production. [Thesis]. FS, KSP
Technical university of Liberec 2008 (in Czech)
[7] HOEK, Z.: Rozmrov zmny odlitk tuhnoucch pi eutektick pemn [Thesis]. FS, KSP Technical university
of Liberec 2011 (in Czech)
[8] Nyrstar materials company (Belgium)