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Die Casting Markets in the Americas Frank Goodwin – International Zinc Association Ryan Winter – Eastern Alloys, Inc.
International Zinc Association
Contents of Presentation • • • •
Introduction Zinc Markets in the Americas Market Trends New Alloys
International Zinc Association
Zinc Market In North & South America
International Zinc Association
Global first uses of zinc in 2014, total consumption 12,976,000 metric tons
Source:IZA, ILZSG
International Zinc Association
Historical Zinc Die Casting Shipments In North America
United States = 88% Mexico = 9% Canada = 3%
International Zinc Association
Latin America Zn Consumption
Source: Votorantim International Zinc Association
Now accepted in Mercosul market
Alloy 5 After 72h salt spray
International Zinc Association
Market Trends
International Zinc Association
Importance Of Die Casting By Industry
Downey 2015 International Zinc Association
Importance Of Specific Manufacturing Technologies To Engineers
Downey 2015 International Zinc Association
Awareness Of Die Casting Technology
Downey 2015 International Zinc Association
Awareness of Die Casting Technology
Downey 2015 International Zinc Association
Why Engineers Specify Die Castings
Downey 2015 International Zinc Association
USA Automotive Lightweighting Trend
Abraham, 2015
International Zinc Association
Automotive Aluminum Forecast
International Zinc Association
International Zinc Association
But For Overall Market
Downey 2015 International Zinc Association
New Alloys
• Introduction to the HF and EZAC® Alloys
International Zinc Association
High Fluidity Alloy (HF)
International Zinc Association
International Zinc Association
Mechanical Properties
International Zinc Association
Physical Properties
International Zinc Association
High Fluidity Alloy (Card Holder)
International Zinc Association
International Zinc Association
EZAC®
International Zinc Association
International Zinc Association
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
International Zinc Association
EZAC® - Higher Strength & Creep Performance
International Zinc Association
EZAC® - Higher Strength & Creep Performance
International Zinc Association
Zinc Casting Alloys Properties
International Zinc Association
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
International Zinc Association
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
0
Plastics
International Zinc Association
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
0
PBT 30%…
10
Plastics
International Zinc Association
Breaking Barriers: Light Zinc! • How to take advantage of the cost effectiveness of the zinc die casting process – even for light components.
International Zinc Association
Weight
Zinc Die Casting Barriers
Creep
International Zinc Association
EZAC® is the strongest die casting alloy available Alloy
Yield Strength (ksi) 57
Hardness (Brinell)
Elongation (%)
Density (g/cc)
120
1
6.49
Zamak 3
32
82
10
6.60
Al380
23
80
3.5
2.71
AZ91D
23
75
3
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
International Zinc Association
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! International Zinc Association
Techniques to improve and measure process!
Textured Die Surfaces
International Zinc Association
Case studies A few successful conversion stories
International Zinc Association
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 customer’s low cost component part target. International Zinc Association
EZAC® - Jam Nut •
•
EZAC® was chosen in this electrical box component due to the application’s high strength requirement. Testing of this application included 30 cycles of tests that are finished in ½ second simulating an explosion of about 3 sticks of dynamite. EZAC® showed no signs of failure in testing.
International Zinc Association
Questions & Answers? Mille grazie!
Ryan Winter +1 914 643 3825 [email protected]
International Zinc Association
International Zinc Association
Contents of Presentation • • • •
Introduction Zinc Markets in the Americas Market Trends New Alloys
International Zinc Association
Zinc Market In North & South America
International Zinc Association
Global first uses of zinc in 2014, total consumption 12,976,000 metric tons
Source:IZA, ILZSG
International Zinc Association
Historical Zinc Die Casting Shipments In North America
United States = 88% Mexico = 9% Canada = 3%
International Zinc Association
Latin America Zn Consumption
Source: Votorantim International Zinc Association
Now accepted in Mercosul market
Alloy 5 After 72h salt spray
International Zinc Association
Market Trends
International Zinc Association
Importance Of Die Casting By Industry
Downey 2015 International Zinc Association
Importance Of Specific Manufacturing Technologies To Engineers
Downey 2015 International Zinc Association
Awareness Of Die Casting Technology
Downey 2015 International Zinc Association
Awareness of Die Casting Technology
Downey 2015 International Zinc Association
Why Engineers Specify Die Castings
Downey 2015 International Zinc Association
USA Automotive Lightweighting Trend
Abraham, 2015
International Zinc Association
Automotive Aluminum Forecast
International Zinc Association
International Zinc Association
But For Overall Market
Downey 2015 International Zinc Association
New Alloys
• Introduction to the HF and EZAC® Alloys
International Zinc Association
High Fluidity Alloy (HF)
International Zinc Association
International Zinc Association
Mechanical Properties
International Zinc Association
Physical Properties
International Zinc Association
High Fluidity Alloy (Card Holder)
International Zinc Association
International Zinc Association
EZAC®
International Zinc Association
International Zinc Association
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
International Zinc Association
EZAC® - Higher Strength & Creep Performance
International Zinc Association
EZAC® - Higher Strength & Creep Performance
International Zinc Association
Zinc Casting Alloys Properties
International Zinc Association
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
International Zinc Association
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
0
Plastics
International Zinc Association
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
0
PBT 30%…
10
Plastics
International Zinc Association
Breaking Barriers: Light Zinc! • How to take advantage of the cost effectiveness of the zinc die casting process – even for light components.
International Zinc Association
Weight
Zinc Die Casting Barriers
Creep
International Zinc Association
EZAC® is the strongest die casting alloy available Alloy
Yield Strength (ksi) 57
Hardness (Brinell)
Elongation (%)
Density (g/cc)
120
1
6.49
Zamak 3
32
82
10
6.60
Al380
23
80
3.5
2.71
AZ91D
23
75
3
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
International Zinc Association
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! International Zinc Association
Techniques to improve and measure process!
Textured Die Surfaces
International Zinc Association
Case studies A few successful conversion stories
International Zinc Association
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 customer’s low cost component part target. International Zinc Association
EZAC® - Jam Nut •
•
EZAC® was chosen in this electrical box component due to the application’s high strength requirement. Testing of this application included 30 cycles of tests that are finished in ½ second simulating an explosion of about 3 sticks of dynamite. EZAC® showed no signs of failure in testing.
International Zinc Association
Questions & Answers? Mille grazie!
Ryan Winter +1 914 643 3825 [email protected]
International Zinc Association
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