North American Die Casting Association May , 2007 Houston, Texas Development of Zinc Die Casting Alloys with Improved Fluidity – Progress in Thin Section Zinc Die Casting Technology Frank E. Goodwin International Lead Zinc Research Organization, Inc., Durham, NC Ke Zhang and Artur B. Filc Teck Cominco Metals Ltd., Mississauga, Ontario Ronald L. Holland, William R. Dalter and Tom M. Jennings Brillcast, Inc., Grand Rapids, Michigan

North American Die Casting Association May , 2007 Houston, Texas Chemical Compositions of Alloy 7 and the New Alloy Alloy Chemical Compositions (wt.%) AlMgCuFePbCdSnNi Alloy 7 1) < Alloy 7 2) < New Alloy 1) 4.50 (4.55) (0.009) (0.060) (0.005) (0.0016) <0.001 (<0.001) <0.001 (<0.001) (0.003) New Alloy 2) 4.52 (4.68) (0.009) (0.057 ) (0.005) (0.001) (0.0002) <0.001 (<0.001) - 1)Optical Emission Spectroscopy (OES) results; 2)Inductively Coupled Plasma (ICP) results Numbers in parentheses are assay results from samples collected at the end of the trial.

North American Die Casting Association May , 2007 Houston, Texas The Four Cavity Die Used in Die Casting Trial Courtesy of CSIR

North American Die Casting Association May , 2007 Houston, Texas Schematic of Stepped Flow Sample

North American Die Casting Association May , 2007 Houston, Texas Die Casting Testing Matrix Test Condition Die Temperature (  C) Fill Time (milliseconds) (350  F) (350  F) (392  F) (392  F) 15

North American Die Casting Association May , 2007 Houston, Texas Full Shots of Alloy 7 (a) (b) Cast at: (a)a die temperature of 200C & a fill time of 25 milliseconds and (b)A die temperature of 200C & a fill time of 15 milliseconds.

North American Die Casting Association May , 2007 Houston, Texas Full Shots of New Alloy Cast at: (a)a die temperature of 200C & a fill time of 25 milliseconds & (b)a die temperature of 200C & a fill time of 15 milliseconds. (a) (b)

North American Die Casting Association May , 2007 Houston, Texas Comparison of Flow Samples Die Temp. 177  C Fill time 25 milliseconds The New Alloy Alloy 7

North American Die Casting Association May , 2007 Houston, Texas Cross Sectional Views of Flow Samples Die Temp. 200  C and a Fill time of 15 milliseconds Alloy 7 The New Alloy

North American Die Casting Association May , 2007 Houston, Texas Microstructure of Flow Samples Cast at Die Temp. 200  C and a Fill time of 15 milliseconds Nital etch Alloy 7 The New Alloy

North American Die Casting Association May , 2007 Houston, Texas Average Flow Distances & Weights of Flow Samples Cast at Different Conditions AlloysDie Temp (  C) Fill Time (milliseconds) Average weight (g) Average flow distance (mm) Alloy New Alloy

North American Die Casting Association May , 2007 Houston, Texas Comparison of Weight & Flow Distance Alloy 7 & New Alloy Samples Cast at a Die Temp. of 177  C And a Fill time of 25 milliseconds

North American Die Casting Association May , 2007 Houston, Texas Variation of Flow Distance Corresponds with variation of fill time for Alloy 7 cast At a die temp. of 177  C and a fill time of 25 milliseconds

North American Die Casting Association May , 2007 Houston, Texas Tensile and Impact Samples

North American Die Casting Association May , 2007 Houston, Texas Mechanical Properties of As- Cast Tensile Samples AlloyTrial#Tensile Strength (MPa) Elongation (%) Impact Energy (Joules) Alloy Alloy Alloy Alloy New Alloy New Alloy New Alloy New Alloy

North American Die Casting Association May , 2007 Houston, Texas Tensile Strength & Elongation of As-Cast Samples Alloy 7 Samples: T1 to T4 New Alloy Samples: T5 to T8

North American Die Casting Association May , 2007 Houston, Texas Mechanical Properties of Aged Samples AlloysTrial # Tensile Strength (MPa) Elongation (%) Impact Energy (Joules) Alloy Alloy New Alloy New Alloy

North American Die Casting Association May , 2007 Houston, Texas Mechanical Properties of Machined Samples AlloysTrial#Tensile Strength (MPa)Elongation(%) Alloy Alloy New Alloy New Alloy

North American Die Casting Association May , 2007 Houston, Texas CONCLUSIONS 1.Successful die casting trial; 2.Carried out to evaluate newly developed Zn die casting alloy; 3.New alloy easy to manufacture & maintain

North American Die Casting Association May , 2007 Houston, Texas Conclusions (Cont’d.) 4.New Alloy had noticeable improvement in fluidity at industrial production conditions, compared to Alloy 7. 5.Microstructure of New Alloy and mechanical properties comparable to Alloy 7. 6.Proves that ultra-thin wall die casting is viable technology for Zn die casting.