1. Panimula
Zinc alloy is a metallic material primarily composed of zinc, with the addition of other elements to enhance specific properties.
These alloying elements can significantly modify characteristics such as strength, tigas na tigas, paglaban sa kaagnasan, and casting ability.
Zinc alloys are widely used in various manufacturing processes due to their relatively low melting point, good fluidity during casting, at pagiging epektibo sa gastos.
2. What is Zinc Alloy?
Zinc is a bluish-white metal. Zinc alloys are metal composites where zinc is the primary constituent, typically alloyed with elements like aluminum (Al), tanso (Cu), magnesiyo (Mg), and trace elements such as nickel (Ni) or titanium (Ti).
These combinations create alloys with tailored mechanical strength, paglaban sa kaagnasan, katatagan, at ibabaw tapusin, making them essential in both structural and decorative applications.
Primary Alloying Elements and Their Roles
| Elemento | Tipikal % in Alloy | Layunin |
| Aluminyo (Al) | 3–27% | Nagpapataas ng lakas, improves fluidity, Pinahuhusay ang paglaban sa kaagnasan |
| Tanso (Cu) | 0.5–3% | Enhances hardness, Paglaban sa Pagsusuot, at lakas ng paghatak |
| Magnesium (Mg) | <0.06% | Grain refinement, improves corrosion resistance |
| Nikel (Ni) | Bakas | Improves strength at elevated temperatures, reduces porosity |
| Titanium (Ti) | Bakas | Enhances creep resistance, used in high-performance alloys |
3. Common Zinc Alloy Families
Zinc alloy is classified based on its composition, mekanikal na pag uugali, and processing method.
The three most prominent families are ZAMAK alloys, ZA alloys, at specialty zinc alloys tulad ng Galfan at Kirksite.
Each group is engineered for specific performance and manufacturing requirements.
ZAMAK Alloys (Sink + Aluminyo + Magnesium + Kupfer (Tanso))
| haluang metal | Komposisyon (Approx.) | Mga Pangunahing Katangian | Mga Karaniwang Aplikasyon |
| ZAMAK 3 | Zn-4%Al-0.03%Mg | Napakahusay na katatagan, dimensional na katatagan | Die-cast parts, mga consumer electronics, hardware na hardware |
| ZAMAK 5 | Zn-4%Al-1%Cu | Higher strength and hardness than ZAMAK 3 | Mga bahagi ng sasakyan, mga bahagi ng istruktura |
| ZAMAK 2 | Zn-4%Al-3%Cu | Highest strength and wear resistance | Industrial gears, bearing housings |
| ZAMAK 7 | Zn-4%Al-0.005%Cu (High purity) | Superior surface finish, lower impurities | Decorative castings, cosmetic components |
Technical Insight:
ZAMAK alloys are hot-chamber die casting materials and are widely used due to their Napakahusay na pagkalikido, low melting points (~385°C), and good dimensional accuracy.
ZAMAK 3 is the most commonly used and is often considered the “benchmark” zinc alloy.
ZA Alloys (Zinc-Aluminum Alloys)
| haluang metal | Komposisyon (Approx.) | Mga Pangunahing Katangian | Mga Karaniwang Aplikasyon |
| ZA-8 | Zn-8%Al-1%Cu | Good strength, suitable for hot-chamber casting | Connector housings, automotive trim |
| ZA-12 | Zn-12%Al-1%Cu | Excellent wear resistance and strength | Industrial components, medium-duty gears |
| ZA-27 | Zn-27%Al-1%Cu | Highest strength in ZA group, magaan ang timbang | Mga bahagi ng istruktura, small engine components |
Technical Insight:
ZA alloys offer higher mechanical strength than ZAMAK due to their increased aluminum content.
They are used primarily in cold-chamber die casting at gravity casting mga proseso. ZA-27, sa partikular na, rivals some aluminum alloys in tensile strength (~400 MPa).
Specialty Zinc Alloys
| haluang metal | Unique Feature | Gamitin ang Kaso |
| Galfan (Zn-5%Al + Rare Earths) | Superior corrosion resistance (2x galvanized steel) | Protective coatings for steel wires and sheets |
| Kirksite (Zn-4%Al + Cu) | Napakahusay na machinability, dimensional na katatagan | Tooling, rubber mold dies, low-volume forming dies |
| Zinc-Copper Alloys (e.g. haluang metal 925) | Improved hardness and machinability | Mechanical hardware, locking mechanisms |
4. Physical Properties of Zinc Alloy
Zinc alloys are valued for their unique balance of low melting point, dimensional na katatagan, and good thermal and electrical conductivity.
These characteristics make them particularly suitable for high-volume die-casting at precision components across multiple industries.
Key Physical Properties
| Pag-aari | Tipikal na saklaw | Yunit | Mga Tala |
| Densidad ng katawan | 6.6 – 6.9 | g/cm³ | Higher than aluminum (~2.7 g/cm³); suitable for damping applications |
| Punto ng Pagtunaw (Solidus–Liquidus) | 370 – 430 | °C | Varies by composition (ZAMAK melts ~385°C; ZA-27 melts ~500°C) |
| Thermal kondaktibiti | 100 – 120 | W/m·K | Mas mababa kaysa sa tanso, but adequate for moderate heat transfer |
| Electrical kondaktibiti | 25 – 30 | % IACS | Lower than copper but sufficient for many low-voltage applications |
| Koepisyent ng Thermal Expansion | 26 – 30 × 10⁻⁶ | /K | Needs consideration in multi-material assemblies |
| Tiyak na Kapasidad ng Init | 390 – 420 | J/kg· K | Moderate thermal inertia |
| Mga Katangian ng Magnetic | Hindi magnetic | – | Suitable for applications where magnetic interference must be avoided |
5. Mechanical Properties of Zinc Alloy
Zinc alloys are renowned for their excellent castability and moderate mechanical strength, especially when used in die casting.
| Pag-aari | ZAMAK 3 | ZAMAK 5 | ZA-8 | ZA-27 | Yunit |
| tunay na lakas ng paghatak | 280 MPa | 330 MPa | 370 MPa | 410 MPa | MPa |
| Yield Lakas | 210 MPa | 250 MPa | 290 MPa | 370 MPa | MPa |
| Pagpapahaba sa Break | 10–13% | 7–9% | 3–6% | 1–3% | % |
| Ang katigasan ng ulo (Brinell) | 82 | 90 | 100 | 120 | HB |
| Modulus ng Pagkalastiko | 83 GPa | 83 GPa | 85 GPa | 96 GPa | GPa |
| Epekto ng Lakas (Charpy) | 2.5–3.0 | 2.0–2.5 | 1.5–2.0 | 1.0–1.5 | J (unnotched) |
6. Paglaban sa kaagnasan & Surface Behavior of Zinc Alloys
Corrosion resistance is a vital property of zinc alloys, particularly for components used in outdoor, marine, or chemically aggressive environments.
Zinc’s Natural Passivation: Paano Ito Gumagana
Kapag nakalantad sa hangin at kahalumigmigan, zinc reacts with oxygen and carbon dioxide to form a thin,
stable layer of zinc carbonate (ZnCO₃), which serves as a protective barrier against further corrosion. This passivation behavior is:
- Self-healing to minor scratches and abrasions
- Effective in atmospheric and mildly acidic/basic environments
- Less protective in chloride-rich (hal., coastal) or acidic industrial settings
Is Zinc Rust？
Technically, rust is a term commonly used to describe the corrosion product of iron and steel, which is mainly iron oxide.
Sink, sa kabilang banda, forms a layer of zinc oxide and zinc hydroxide when it corrodes. While this is not the same as rust, it is still a form of corrosion.
Gayunpaman, the corrosion products of zinc are generally more adherent and protective compared to rust, which helps to slow down the further corrosion of the metal.
Surface finishing: pag plating, patong ng pulbos, chromate conversion
To enhance the corrosion resistance and aesthetic appeal of zinc alloys, various surface finishing techniques are used:
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Electroplating with metals such as nickel, Chrome, or zinc-nickel alloys is a common surface finishing method.
Plating provides an additional layer of protection against corrosion and can also improve the appearance of the product.
Halimbawa na lang, nickel-plating can give zinc alloy parts a shiny, durable surface that is resistant to scratches and corrosion.
Patong ng pulbos:
Powder coating involves applying a dry powder to the surface of the zinc alloy part and then curing it under heat.
This forms a hard, protective film that offers good corrosion resistance and a wide range of color options.
Powder-coated zinc alloy products are often used in outdoor applications, such as furniture and architectural hardware.
Chromate conversion:
Chromate conversion coating involves treating the zinc alloy surface with a chromate solution to form a thin, proteksiyon layer.
This layer provides good corrosion resistance and can also improve the adhesion of subsequent coatings, tulad ng pintura o powder coating.
Gayunpaman, due to environmental concerns related to hexavalent chromium (a component of traditional chromate solutions), there is a growing trend towards using trivalent chromium or chromium-free alternatives.
7. Paggawa & Fabrication Processes
Die casting (hot-chamber, cold-chamber)
Hot-chamber die casting:
In hot-chamber mamatay sa paghahagis, also known as gooseneck die casting, the melting pot is an integral part of the casting machine.
The molten zinc alloy is forced into the die cavity by a plunger through a gooseneck-shaped injection system.
This process is suitable for small-to medium-sized parts with relatively simple geometries. It offers high production rates and good dimensional accuracy.
Gayunpaman, it is limited by the size of the melting pot and the type of alloy that can be used, as some alloys may react with the metal of the melting pot.
Cold-chamber die casting:
Cold-chamber die casting is used for larger parts and alloys that are more prone to oxidation or have higher melting points.
Sa prosesong ito, the molten zinc alloy is ladled into a separate injection chamber, and then a plunger forces the alloy into the die cavity.
Cold-chamber die casting provides better control over the injection process and can handle larger volumes of molten metal, making it suitable for complex-shaped and larger-sized components.
Investment casting and Sand casting
Buhangin paghahagis:
Buhangin paghahagis is a traditional method for casting zinc alloys. A pattern of the desired part is used to create a mold cavity in a sand mixture.
The sand mold is then filled with molten zinc alloy, which solidifies to form the part.
Sand casting offers great flexibility in terms of part design, as it can accommodate complex shapes and large sizes.
Gayunpaman, it generally has lower dimensional accuracy and surface finish compared to die casting.
Sand-cast zinc alloy parts are commonly used in the production of large-scale industrial components, custom-made parts, and some architectural elements.
Pamumuhunan sa paghahagis:
Pamumuhunan sa paghahagis, kilala rin bilang lost-wax casting, is used for producing high-precision zinc alloy parts with complex geometries.
Sa prosesong ito, a wax model of the part is made, na kung saan ay pagkatapos ay pinahiran na may isang ceramic shell.
The wax is melted out, leaving a cavity into which molten zinc alloy is poured.
Investment casting allows for the production of parts with very fine details and a high-quality surface finish, but it is a more expensive and time-consuming process compared to die casting and sand casting.
Gravity Casting
Gravity casting, or permanent mold casting, involves pouring molten zinc alloy into a mold cavity under the force of gravity.
The mold is usually made of metal, such as cast iron or steel, and can be reused multiple times.
This process is suitable for producing larger parts or parts with simpler geometries.
Gravity-cast zinc alloy parts often have a smoother surface finish and can be more cost-effective for lower-volume production runs.
It is used in applications where high-precision casting is not the primary requirement, such as in some decorative items and certain types of industrial components.
Paglabas, pagkukubli, at pagtatak
Paglabas:
It is used to produce continuous profiles with a fixed cross-section from zinc alloys.
A billet of the alloy is forced through a die, which gives the material its desired shape. This process is suitable for creating products such as rods, mga tubo, and various structural profiles.
Gayunpaman, extrusion of zinc alloys is less common compared to other metals due to their relatively low strength and the potential for surface defects during the process.
Pagbubuo ng mga:
Forging involves shaping the zinc alloy by applying compressive forces, usually using hammers or presses.
This process can improve the mechanical properties of the alloy by refining the grain structure and eliminating internal defects.
Gayunpaman, forging zinc alloys is challenging due to their low melting point and relatively poor hot-working properties.
Stamping:
Stamping is a process used to form flat sheets of zinc alloy into various shapes by applying pressure with a die.
It is commonly used in the production of sheet-metal components, such as automotive body parts and household hardware.
Stamping of zinc alloys requires careful consideration of the alloy’s formability and the design of the dies to avoid cracking and other defects.
8. Applications of Zinc Alloy
Zinc alloy is known for excellent castability, good strength-to-weight ratio, paglaban sa kaagnasan, and ability to form complex shapes with tight tolerances.
Industriya ng Automotive
Zinc alloys are heavily used in both structural and decorative automotive components due to their tibay ng katawan, dimensional na katatagan, at pagiging epektibo sa gastos.
Mga Karaniwang Aplikasyon:
- Door handles and window cranks
- Carburetor housings
- Emblem frames and trim parts
- Seat belt components
- Fuel system fittings
Mga Elektronika ng Consumer & Hardware
Zinc alloys are widely applied in electronic device housings and internal components due to their EMI shielding capabilities and electrical kondaktibiti.
Mga Pangunahing Aplikasyon:
- Smartphone housings
- Laptop hinges and frames
- Remote controls and set-top boxes
- Camera and drone casings
- Cable connectors and terminals
Arkitektura & Building Hardware
Due to their resistance to corrosion and attractive finishes, zinc alloys are commonly used in architectural applications.
Karaniwang Mga Produkto:
- Door handles and locks
- Window fittings and hinges
- Curtain wall anchors
- Decorative panels
- Plumbing fittings
Industrial and Mechanical Components
Sink's dimensional na katatagan, machinability, at Paglaban sa Pagsusuot make it well-suited for a variety of mechanical assemblies.
Used In:
- Gears and levers
- Bearing housings
- Pulleys and brackets
- Pneumatic and hydraulic systems
Pandekorasyon & Fashion Accessories
Zinc alloys are popular in the fashion and luxury goods industries because they’re easy to cast and finish with gold, Chrome, or antique-style coatings.
Common Items:
- Belt buckles
- Costume jewelry
- Buttons, zippers, and snaps
- Keychains and emblems
Mga Laruan, Gifts & Novelty Items
Zinc die-casting enables the mass production of small, detailed components, making it a great choice for toys and collectibles.
Mga Halimbawa:
- Model cars and planes
- Board game pieces
- Trophies and medals
- Miniature figurines
Marine & Corrosion-Prone Environments
Zinc’s natural resistance to corrosion, particularly in mildly saline environments, makes it useful for marine mga aplikasyon.
Mga Aplikasyon:
- Boat hardware and cleats
- Anodes for galvanic protection
- Saltwater fittings and housings
9. Key Benefits of Zinc Alloy
Napakahusay na katatagan
- Ideal for complex shapes, Mga Detalye ng Fine, and thin-walled parts
- Mababang punto ng pagtunaw (~385–425°C) allows energy-efficient casting and extended mold life
High Dimensional Accuracy
- Minimal shrinkage provides tight tolerances (±0.05 mm or better)
- Suitable for precision components without extensive post-processing
Strong Mechanical Properties
- Tensile strength up to 280 MPa (hal., Zamak 3)
- Good hardness and rigidity, often superior to aluminum alloys in small castings
Paglaban sa kaagnasan
- Naturally forms a protective oxide layer
- Compatible with additional coatings like chrome plating, patong ng pulbos, or passivation for enhanced durability
Aesthetic & Finish Flexibility
- Smooth surface finish suitable for high-end decorative parts
- Supports polishing, pagsusuklay ng mga, pagpipinta, pag electroplating (hal., nikel, Chrome, ginto na)
Produksyon na Epektibo sa Gastos
- Lower energy consumption than aluminum or magnesium
- Long mold life reduces tooling costs
- High recyclability contributes to lower lifecycle costs
Fast Production Cycles
- Especially in hot-chamber die casting, cycles can be as short as 3–5 seconds
- Enables high-volume, automated manufacturing with reduced labor
Excellent Joinability
- Supports mechanical fastening, soldering, and adhesive bonding
- Compatible with inserts and threaded components for functional assemblies
Superior Wear Resistance
- Durable in high-friction applications like locks, mga gears, and moving assemblies
- Good fatigue performance in cyclic loading conditions
Low Tool Wear
- Zinc alloys are less abrasive than aluminum during casting
- Molds can often exceed 500,000–1,000,000 shots before replacement
10. Comparison of Zinc Alloy with Competing Materials
| Pag-aari | sink haluang metal | aluminyo haluang metal | Magnesium Alloy | Mga plastik sa Engineering |
| Densidad ng katawan (g/cm³) | 6.6–6.9 | 2.6–2.8 | 1.7–1.9 | 0.9–1.8 |
| Punto ng Pagtunaw (°C) | 385–425 | 600–660 | 620–650 | Iba-iba ang (karaniwan ay <300) |
| Lakas ng Paghatak (MPa) | 250–300 (hal., Zamak 3) | 180–310 | 200–250 | 50–120 |
| Ang katigasan ng ulo (Brinell) | 80–120 | 50–100 | 30–70 | 10–40 |
| Katatagan | Napakahusay | Mabuti na lang | Katamtaman | Not suitable for casting |
Machinability |
Napakahusay | Mabuti na lang | Fair | Poor to Moderate |
| Paglaban sa kaagnasan | Mabuti na lang (with coatings: very good) | Katamtaman (needs anodizing/coating) | Fair to Good (oxidation prone) | Napakahusay (inert polymers) |
| Tapos na sa ibabaw | Napakahusay (makinis na, polishable) | Mabuti na lang | Fair | Katamtaman (matte to glossy) |
| Gastos (Materyal + Pagproseso ng) | Mababa ang | Katamtaman | Mataas na | Low to Medium |
| Epekto sa Kapaligiran | Maaaring i-recycle, low-energy casting | Higher energy use, Maaaring i-recycle, | Maaaring i-recycle, higher environmental cost | Partially recyclable, petroleum-based |
| Dimensional na katumpakan | Napakahusay | Mabuti na lang | Mabuti na lang | Katamtaman (prone to shrinkage/warping) |
Key Comparative Takeaways
- Zinc vs Aluminyo
Zinc offers better dimensional accuracy, finer surface finish, and shorter casting cycle times.
Aluminyo, while lighter, requires more energy to process and often needs post-finishing (hal., pag anod ng) para sa paglaban sa kaagnasan. - Magnesium vs Zinc
Magnesium is the lightest metal but has poorer corrosion resistance, lower surface quality, and higher processing cost.
Zinc is more stable, mas madali sa machine, and more suitable for small precision parts. - Zinc vs Engineering Plastics
Plastics are lightweight and corrosion-free but lack mechanical strength and wear resistance.
Zinc alloys bridge the gap between metals and plastics in terms of strength, hitsura, at gastos, especially in die-cast components.
11. Pangwakas na Salita
From their humble beginnings to the current state-of-the-art applications, zinc alloys have continuously evolved to meet the changing demands of various industries.
Their unique combination of properties, pagiging epektibo ng gastos, and versatility makes them a material of choice in countless products.
The ongoing research and development efforts in areas such as nanostructuring, green manufacturing, function integration, and computational design are paving the way for the next generation of zinc alloys.
These advancements will not only address the existing limitations of zinc alloy but also open up new opportunities in emerging fields.
Mga FAQ
Is zinc alloy strong and durable?
Oo nga. Mga haluang metal ng sink, especially Zamak series alloys, offer good tensile strength (hanggang sa 300 MPa) at magsuot ng resistensya.
Habang hindi kasing lakas ng bakal, they are durable enough for many structural and mechanical applications.
Does zinc alloy rust or corrode?
Zinc alloys do not rust like iron, but they can corrode under certain environmental conditions.
Gayunpaman, they naturally form a protective oxide layer and can be further protected with coatings like plating or powder coating.
Is zinc alloy jewelry safe?
Oo nga, most zinc alloys used in jewelry are safe, especially when nickel-free and properly coated.
Gayunpaman, individuals with metal sensitivities should confirm the alloy composition and surface finish.
Can zinc alloy be recycled?
Ganap na. Zinc alloys are highly recyclable and can be re-melted without significant degradation in quality.
This makes them an environmentally responsible choice for mass production.
Is zinc alloy magnetic?
Hindi. Zinc and its alloys are non-magnetic, making them suitable for use near sensitive electronic equipment.
What are the disadvantages of zinc alloy?
The main drawbacks include relatively high density (heavier than aluminum or magnesium), mas mababang punto ng pagtunaw (which limits high-temperature applications), and potential brittleness under certain conditions.
