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Frank E. Goodwin International Lead Zinc Research Organization, Inc., Durham, NC

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

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Frank E. Goodwin International Lead Zinc Research Organization, Inc., Durham, NC

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  1. 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 15 - 18, 2007 Houston, Texas

  2. Chemical Compositions of Alloy 7 and the New Alloy 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 15 - 18, 2007 Houston, Texas

  3. The Four Cavity Die Used in Die Casting Trial Courtesy of CSIR North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  4. Schematic of Stepped Flow Sample North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  5. Die Casting Testing Matrix North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  6. Full Shots of Alloy 7 (b) (a) • Cast at: • a die temperature of 200C & a fill time of 25 milliseconds and • A die temperature of 200C & a fill time of 15 milliseconds. North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  7. Full Shots of New Alloy (b) (a) • Cast at: • a die temperature of 200C & a fill time of 25 milliseconds & • a die temperature of 200C & a fill time of 15 milliseconds. North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  8. Comparison of Flow Samples Die Temp. 177C Fill time 25 milliseconds The New Alloy Alloy 7 North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  9. 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 15 - 18, 2007 Houston, Texas

  10. 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 15 - 18, 2007 Houston, Texas

  11. Average Flow Distances & Weights of Flow Samples Cast at Different Conditions North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  12. 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 15 - 18, 2007 Houston, Texas

  13. 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 15 - 18, 2007 Houston, Texas

  14. Tensile and Impact Samples North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  15. Mechanical Properties of As-Cast Tensile Samples North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  16. 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 15 - 18, 2007 Houston, Texas

  17. Mechanical Properties of Aged Samples North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  18. Mechanical Properties of Machined Samples North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  19. CONCLUSIONS • Successful die casting trial; • Carried out to evaluate newly developed Zn die casting alloy; • New alloy easy to manufacture & maintain North American Die Casting Association May 15 - 18, 2007 Houston, Texas

  20. Conclusions (Cont’d.) • New Alloy had noticeable improvement in fluidity at industrial production conditions, compared to Alloy 7. • Microstructure of New Alloy and mechanical properties comparable to Alloy 7. • Proves that ultra-thin wall die casting is viable technology for Zn die casting. North American Die Casting Association May 15 - 18, 2007 Houston, Texas

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