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Die Casting Markets in the Americas

Frank Goodwin International Zinc Association


Ryan Winter Eastern Alloys, Inc.

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Contents of Presentation

Introduction
Zinc Markets in the Americas
Market Trends
New Alloys

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Zinc Market In North & South America

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Global first uses of zinc in 2014, total consumption 12,976,000 metric tons

Source:IZA, ILZSG

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Historical Zinc Die Casting Shipments


In North America

United States = 88%


Mexico = 9%
Canada = 3%

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Latin America Zn Consumption

Source: Votorantim
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Now accepted in Mercosul market

Alloy 5 After 72h salt spray

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Market Trends

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Importance Of Die Casting By Industry

Downey 2015
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Importance Of Specific Manufacturing


Technologies To Engineers

Downey 2015
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Awareness Of Die Casting Technology

Downey 2015
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Awareness of Die Casting Technology

Downey 2015
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Why Engineers Specify Die Castings

Downey 2015
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USA Automotive Lightweighting Trend

Abraham, 2015

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Automotive Aluminum Forecast

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But For Overall Market

Downey 2015
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New Alloys

Introduction to the HF and EZAC Alloys

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High Fluidity Alloy (HF)

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Mechanical Properties

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Physical Properties

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High Fluidity Alloy (Card Holder)

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EZAC

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Net
Shape
Consolidation
No Machining

Finishing
Costs

Cost
Savings
of Die
Casting

4X
Shorter
Cycle
Time
Aluminum

1/10
Tooling
Cost of
Aluminum

Lower
Energy
Costs

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EZAC - Higher Strength & Creep


Performance

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EZAC - Higher Strength & Creep


Performance

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Zinc Casting Alloys Properties

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Other Metals

PBT 30% glass

Nylon 66/6

PP

ABS

Ductile Iron

C93200 Cu

AZ-91D Mg

A380 Al

ZA-27

ZA-12

ZA-8

Zn #3

Zn #5

Zinc Alloys

EZAC

Yield Strength (MPa)

450
400
350
300
250
200
150
100
50
0

Plastics

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Hardness (BHN)
180
160

140
120
100
80
60
40
20
PBT 30%
glass

Nylon 66/6

PP

ABS

Ductile Iron

Other Metals

C93200 Cu

A380 Al

EZAC

AZ-91D Mg

Zinc Alloys

ZA-27

ZA-12

ZA-8

Zn #5

Zn #3

Plastics

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Impact Strength (J)


70
60
50
40

30
20

PP

ABS

Nylon 66/6

Other Metals

Ductile Iron

C93200 Cu

A380 Al

EZAC

AZ-91D Mg

Zinc Alloys

ZA-27

ZA-12

ZA-8

Zn #5

Zn #3

PBT 30%

10

Plastics

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Breaking Barriers: Light Zinc!


How to take advantage of the cost
effectiveness of the zinc die casting
process even for light components.

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Weight

Zinc Die
Casting
Barriers

Creep

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EZAC is the strongest die casting


alloy available
Alloy

Yield
Strength
(ksi)
57

Hardness
(Brinell)

Elongation
(%)

Density
(g/cc)

120

6.49

Zamak 3

32

82

10

6.60

Al380

23

80

3.5

2.71

AZ91D

23

75

1.81

EZAC

EZAC is 2.5X heavier than Al380.


EZAC is also 2.5X Stronger and 2.5X
more fluid than Al380.

Cast EZAC 2.5X thinner

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How to make Light Zinc?


Since EZAC is 2.5X stronger
and more fluid than Aluminum
Cast it 2.5X thinner.
For Example An aluminum
part that has an average
thickness of 0.125. If we cast
design & cast this part in EZAC
at 0.05 there is no penalty in
weight or strength It is only
less expensive to produce.
BUT NOT EASY!
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Techniques to improve and measure


process!

Textured Die Surfaces

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Case studies
A few successful conversion stories

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EZAC - Baseplate

The customer of this high


volume component required a
low cost die cast product with
high strength, hardness and
wear resistance due to a
mating application with a steel
spring. Prototypes successfully
passed in machined Aluminum
7075, but due to the high
machining cost, alternative
sources were required.
Zamak 2 casting prototypes
were produced but failed the
customers wear test. Seybert
Casting introduced EZAC as
an alternative which
subsequently passed all the
customers prototype
requirements. Fielding Mfg
built the tool and delivered
EZAC die cast parts in
volume, while meeting the
customers low cost component
part target.
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EZAC - Jam Nut

EZAC was chosen in this


electrical box component due
to the applications high
strength requirement.
Testing of this application
included 30 cycles of tests
that are finished in second
simulating an explosion of
about 3 sticks of dynamite.
EZAC showed no signs of
failure in testing.

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Questions & Answers?


Mille grazie!

Ryan Winter
+1 914 643 3825
rwinter@eazall.com

International Zinc Association

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