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The classical use for zinc alloy die castings for plated trim and non-structural applications is being supplemented with new engineered applications. New alloys such as ZA-27 offer higher strengths than #3, which when combined with cost effective, net shape capability of the die casting process provide new opportunities in automotive component design. A systematic design strategy must, however, become part of the product design process. This strategy, by evaluating mechanical and physical properties of the material against use requirements, offers the best methodology for new and replacement applications.

Progress in recent alloy development work has resulted in the commercialization of a high strength, creep resistant, hot chamber zinc based die casting alloy. The work was based upon earlier research conducted under the sponsorship of the Department of Energy Cast Materials Consortium (CMC). Refinement of alloy chemistry produced significant improvements in tensile strength, hardness and creep performance. Because the composition of this new alloy is near that of the Aluminum/Copper/Zinc ternary eutectic, the low melting temperature enables the alloy to be cast in a hot chamber die casting machine without excessive wear of shot end components typically experienced with other high-copper zinc die casting alloys contents such as ACuZinc 5.

New high performance ZA casting alloys (ZA-8, 2A-12 & ZA-27) provide superior mechanical properties which designers can apply using die casting technology. This paper is intended to assist the automotive industry and their suppliers to better understand the capabilities and property advantage of the new alloys for new product designs. Reviewed are the general properties of the ZA alloy family, their die casting characteristics and several examples where ZA die castings have lowered manufacturing costs and/or improved product performance. Included are recent automotive developments.