International Journal of Engineering and Technical Research (IJETR)

ISSN: 2321-0869 (O) 2454-4698 (P), Volume-4, Issue-1, January 2016

Study of Mechanical Properties of Zn-27Al Alloy

Cast in Metal Mould at Different Casting Conditions
Rumana Akhter, Md Rofiqul Islam
compete with other mature alloy systems, such as brasses,
Abstract In the last forty years a series of zinc-aluminum bronzes, aluminum based alloys and cast irons [3].
alloys, termed ZA alloys have been developed to compete with The ZA alloys are suitable for casting by a variety of methods
well known alloys such as brasses, bronzes and cast irons. The including permanent mould and high-pressure die casting.
ZA alloys are well suited to applications requiring high cast Advantages are often associated with the use of the ZA alloys
strength, hardness and wear resistance. The alloy ZA-27 looks
include high mechanical properties, low melting energy
particularly attractive. It can be used for the manufacture by
gravity sand casting and permanent mould casting of complex
consumption, machinability, and excellent bearing
parts characterized by tensile strength well over 400Mpa. The characteristics and wear resistance [4].
aim of this study is to produce commercially available ZA-27 Zn-Al system offers the advantage of unlimited solubility,
alloy cast in metal mould and to study its mechanical properties without its leading to the formation of deleterious
at different casting conditions. A cast iron metal mould was intermetallic compounds. Depending on the aluminum
prepared and ZA-27 alloy was cast at different conditions. The content under consideration, the freezing range can however,
casting variables were pouring temperatures of the melt. vary substantially, and the as cast microstructure can exhibit
Casting was conducted at pouring temperatures 650C, 700C very distinct features. All the Zn-Al alloys now commercially
and 750C where the mould preheat temperature was fixed at available are strengthened by copper and magnesium
300C. To determine the mechanical properties tensile and
additions. The former induces the occurrence of
hardness test were performed. The best combination of
mechanical properties for the alloy ZA-27 cast in metal mould supplementary phase which do not derive from the binary
was obtained at melt pouring temperature 700C. equilibrium diagram. In this connection it must be pointed out
that, on top of its hardening and unfortunately enough
embrittling effect, Mg helps increase the resistance to
Index Terms Casting, metal, mould, ZA-27 alloy, hardness, intergranular corrosion. On the other hand, cu improves creep
tensile strength, pouring temperature, preheat temperature, and corrosion behaviors [5].
percentage elongation, ductility The economic benefits and inherent properties of ZA alloys
account for their use in a rapidly growing list of industrial
applications, including: industrial fittings and hardware,
I. INTRODUCTION pressure tight housings, sleeve bearings, thrust washers, wear
Hypoeutectic zinc-aluminum alloys have been used since the plates, electrical switchgear and hardware, hose couplings
year 1930. These alloys are based on the hypoeutectic Zn-4Al and connectors, fire fighting hardware, pneumatic and
composition. These alloys are primarily used for die casting hydraulic cylinder components, pulleys and sheaves,
applications due to their superior properties. They display non-sparking mining hardware, decorative hardware etc [6].
excellent cast ability, easy finishing, are economical and One of these alloys is particularly attractive, as it combines
possess good mechanical strength [1]. With such properties very high strength (typically well over 400 MPa) and
they are used for a wide range of decorative and light moderate density. It was developed by NORDANA under the
structural parts and lend themselves readily to rapid mass trade name of ZA-27, which is meant to indicate that it
production techniques. These factors account for their contains about 27%Al (Zn-27Al-2Cu-0.015Mg) [7].
widespread use in the automotive industry. The range of The strength of the zinc-aluminum alloy increases with the
zinc-aluminum alloys was expanded in the last fifty years by aluminum content, so that the 27% aluminum alloys have a
the introduction of a series of hypereutectic zinc-aluminum high tensile strength. The Zn-Al system has a eutectic at
alloys [2]. approximately 5% aluminum, so that in the commercial alloys
These hypereutectic alloys are commonly referred to as the temperature range over which freezing occurs also
foundry or ZA (for Zinc-Aluminum) alloys. In the year increases as the aluminum content increases until in the case
1962, the International Lead Zinc Research Organization of 27% aluminum alloy, the freezing range is nearly 109C.
(ILZRO) introduced IIZRO 12(since referred to as ZA-12) Its freezing range is wide particularly in comparison with its
containing 11%Al-0.75%Cu-0.02%Mg. In the late 1970s, the low liquidus temperature [8]. This naturally makes it prone to
Noranda Research Centre developed two additional alloys, solidification micro shrinkage, and then casting conditions
ZA-8 and ZA-27 (the 8 and 27 refer to the approximate must then be chosen carefully, in order to secure the internal
weight percent of aluminum). The alloys were developed to soundness [9].
The aim of this study is to produce commercially available
ZA-27 alloy cast in metal mould at different casting
Rumana Akhter, Department of Materials and Metallurgical conditions and to compare its properties with those of
Engineering Bangladesh University of Engineering and Technology,Dhaka, aluminum and copper base alloys. Considering the
Bangladesh importance of suitable foundry alloys, it is necessary to
Md Rofiqul Islam,Department of Materials and Metallurgical understand the production process of zinc aluminum foundry
Engineering Bangladesh University of Engineering and Technology,Dhaka,
Bangladesh
alloy and the metallurgy behind in optimize various

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 Study of Mechanical Properties of Zn-27Al Alloy Cast in Metal Mould at Different Casting Conditions

parameters to produce sound casting. It is also necessary to Mould used: Permanent mould of cast iron
verify its suitability as foundry alloy compared to other alloys. Alloy used: ZA-27
In this project permanent metal mould was used which has
various advantages. There is no need to make the mould Additives used: Copper 1% and Magnesium 0.02%
again. It is less time consuming. It is cost effective in terms of Casting variables: Pouring Temperature
mass production. The alloy is so chosen that ZA-27 is about Preheat temperature of the mould: 300C
17% lighter than ZA-11 and 21% lighter than ZA-8. The Pouring temperatures of the melt:
electrical conductivity is higher than ZA-11 and ZA-8. The 1. 650C
ductility of ZA-27 is higher than these two alloys. ZA-27 is 2. 700C
significantly more creep resistant [10]. ZA-27 alloy can be 3. 750C
recommended for stress application up to 150C. As
permanent mould is used here smooth surface finish of the
cast is desirable. It requires less material than sand casting and C. Melt Practice
also eliminates the operation of machining and grinding. Experimental zinc-aluminum alloys were prepared using
special high grade zinc (99.99% min), commercial purity
aluminum (99.95%min), electrolytic tough pitch copper
II. EXPERIMENTAL PROCEDURE (99.99%min), and commercial purity magnesium (99.8%
min). In this experiment the alloy was melted in a pit furnace.
A. Mould making Since aluminum does not dissolve readily in molten zinc, the
Cast iron was chosen for mould making. The mould block was aluminum was melted first, along with any copper addition.
sand cast and grinding was done. Extra feeder part was Zinc was added to aluminum and magnesium was preferably
removed by hacksaw from the proposed block. introduced just before casting.

The alloyed bath was stirred vigorously to ensure batch

homogeneity and allowed to rest prior to skimming. The alloy
was transferred to the mould using suitable ladles and pouring
was done to prevent skimming from being entrained. The
experimental alloy was cast in to standard test pieces using
well established casting patterns.

Before preheating the mould, a coating was applied in to the

mould. In this experiment calcium carbonate was used as a
coating material. After coating the mould was used with a gas
flame. The mould was heated as it got uniform temperature
over the entire mould. To obtain the desired preheat
Fig. 1. Sand cast block of cast iron with feeder temperature the surface temperature were measured at various
locations and average temperature was taken as the preheat
After sand casting the blocks were given proper dimension by temperature.
machining. Then two cope parts were joined together with
screws. Sprue cavity and specimen cavities were made by The ladle was removed from the furnace and melt temperature
thorough drilling. was measured with a thermocouple. When the melt
The drag part was machined to obtain the runner and sprue temperature reached to the desired pouring temperature the
base cavity. In this case milling was done by the milling melt was poured into the mould. The pouring was done
machine and the material was removed from the block carefully so that mould cavity was filled with the liquid metal.
forming the desired shape. Then the casting was allowed to cool. Then the solidified
casting was removed from the mould.

III. DETERMINATION OF PROPERTIES

The samples of all the three casting conditions were subjected

to hardness and tensile test. The %elongation was also
measured. All the results of hardness test and tensile test were
tabulated in Table1, Table2, and Table3.
D. Hardness Test
The hardness of the samples was measured by using
Brinnel hardness testing machine. The indentations were
made on the specimens using 100kg load for 30 seconds.
Fig. 2. Milling the drag part of the mould

B. Casting Condition Table 1: Measured Hardness of all samples cast at different

pouring temperature

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 International Journal of Engineering and Technical Research (IJETR)
ISSN: 2321-0869 (O) 2454-4698 (P), Volume-4, Issue-1, January 2016

Pouring Sample Hardness Average Pouring Sample UTS Average

Temperature(C) No. Hardness Temperature(C) No. (MPa) UTS
(HRB)
(HRB) (MPa)
1 40.3 1 266.3
2 42.3 2 258.8
650 3 48.9 38 650 3 258.3 258.8
4 38.2 4 260.3
5 32.5 5 253.2
6 25.8 6 255.8
1 41.2 1 292.2
2 43.8 2 299.8
700 3 42.9 43.33 700 3 297.9 296.5
4 43.8 4 296.8
5 42.5 5 293.5
6 45.8 6 298.8
1 49.9 1 259.9
2 45.6 2 263.6
750 3 53.6 49.35 750 3 259.6 257.7
4 50.2 4 248.2
5 42.5 5 254.5
6 54.3 6 260.3

Hardness of ZA-27 alloy cast at different pouring

Fig. 3. Tensile strength of
Fig. 4. ZA-27 alloy cast at different
temperature pouring temperature

From Fig.3 as the pouring temperature increases the hardness Fig.4 shows as pouring temperature increases UTS increases.
of ZA-27 alloy increases. From Table1 maximum hardness Then further increase in pouring temperature causes decrease
54.3 was obtained with the specimen cast at pouring in UTS. From Table2 maximum tensile strength 299.8 MPa
temperature 750C. was obtained with the specimen cast at pouring temperature
700C.
E. Tensile test

Tensile strength and ductility of the samples were measured

by using a Universal Testing Machine and have been
tabulated in Table2 and Table3.
Table 2: Measured Tensile Strength of all samples cast at
Table 3: Measured %elongation of ZA-27 alloy cast at
different pouring temperature
different pouring temperature

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 Study of Mechanical Properties of Zn-27Al Alloy Cast in Metal Mould at Different Casting Conditions

As the pouring temperature increases the hardness of

Pouring Sample Elongation Average % ZA-27 alloy increases.
Temperature( No. mm elongation Maximum hardness 54.3 was obtained with the
C) specimen cast at pouring temperature 750C.
650 1 0.0 0.1 The best combination of mechanical properties for the
2 0.1 alloy ZA-27 cast in metal mould was obtained at
700 1 1.0 1.7 melt pouring temperature 700C and mould preheat
2 0.7 temperature 300C.
750 1 0.3 1.2
2 0.9
REFERENCES

[1] M. Lamberights. G. Waimaz. D. Coutsouradis, P. Delneuvile. M.

Mecus. Friction and Ductility Behaviors of a High Strength Zinc
Foundry Alloy
[2] F. Gervis, H. I. Evert. M. Bess, The Development of a Family of
Zinc-Base Foundry Alloys AFS Transactions Vol.88 (1980)
[3] R.J. Barnhurst. E. Gervis. F.D. Bavies. Gravity casting of
Zinc-Aluminum Alloys- Solidification Behavior of ZA-8, ZA-12 and
ZA-27 AFS Transactions Vol (1980)
[4] Johan P. Verwjs The Modification of Silicon in Zn-Al-Si Alloys
Technical University of Nova Scotia, 1997.
[5] F. Ilabiby. M.J. McNallan. Macrosegregation and Underside
Shrinkage in Sand Cast Zinc27%-Aluminum Alloy Vol.92 (1984)
[6] Goldak, GR.parr, J.G. A High-Temperature X-Ray-Diffractometer
Study of the Zinc-Aluminum System in the Region 40-75 wt%Zinc, J.
Inst Metals. V 92. 1964. P.230
[7] Hansen. M.. Der Aufbau der Zweistoftleairunqcn The Structure of
Binary Alloys, Verlag von Julius Springer. Berlin. 1936. P.164
Fig. 5.%elongation of ZA-27 alloy cast at different pouring
[8] Massalski. T.B. Binary Alloy Phase Diagrams Metals park.
temperature Ohio.1986
Fig.5 states that as pouring temperature increases percentage [9] Larsson. 1. R. Pre-precipitation and Precipitation Phenomena in the
elongation increases. Then further increase in pouring Al-Zn Systems Acta Met., V 16. 1967. Pp. 35-44
temperature decreases % elongation. Maximum ductility was [10] An Mey. S. Reevaluation of the Al-Zn System Z-Metallkd.
observed with the specimen cast at pouring temperature V84.1993. P.453
700C.

IV. CONCLUSION
From the present experiment the following conclusions can be
drawn
As pouring temperature increases tensile strength
increases but above 700C the tensile strength
decreases. As pouring temperature increases grain
size become smaller which strengthen the structure
and a higher tensile strength can be achieved. But at
higher temperature increases the oxidation rate
which ultimately reduces the tensile strength of the
cast alloy.
Maximum tensile strength 299.8 MPa was obtained
with the specimen cast at pouring temperature
700C.
With the increase in pouring temperature of the melt
percentage elongation increases. But beyond 700C
of the melt the cast alloy shows less ductility. As
pouring temperature increases solidification rate
increases and grain size becomes smaller. So %
elongation increases. Hence, ductility of the cast
alloy increases. But at higher pouring temperature
higher oxidation rate reduces the ductility of the cast
alloy.
Maximum ductility was observed with the specimen
cast at pouring temperature 700C.

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