Crystal Structure of

Aluminum, Zinc, and their

Alloys
By: Omar Fajardo
Sebastian Henao
Devin Baines
ENGR45, F2014, SRJC
 Purpose

The purpose of this experiment was to examine and observe the

microstructure of aluminum, zinc, and their alloys.
 Aluminum
• “Aluminium (or aluminum; see spelling differences) is a chemical element in the boron group with
symbol Al and atomic number 13. It is a silvery white, soft, ductile metal. Aluminium is the third
most abundant element (after oxygen and silicon), and the most abundant metal in the Earth's
crust. It makes up about 8% by weight of the Earth's solid surface. Aluminium metal is so
chemically reactive that native specimens are rare and limited to extreme reducing environments.
Instead, it is found combined in over 270 different minerals. The chief ore of aluminium is bauxite.

• Aluminium is remarkable for the metal's low density and for its ability to resist corrosion due to
the phenomenon of passivation. Structural components made from aluminium and its alloys are
vital to the aerospace industry and are important in other areas of transportation and structural
materials. The most useful compounds of aluminium, at least on a weight basis, are the oxides and
sulfates.”
• Source: Wikipidia
• Atomic number 13
• Standard atomic weight 26.9815385(7)
 Zinc

• “Zinc, in commerce also spelter, is a chemical element with symbol Zn and atomic
number 30. It is the first element of group 12 of the periodic table. In some respects
zinc is chemically similar to magnesium: its ion is of similar size and its only
common oxidation state is +2. Zinc is the 24th most abundant element in the
Earth's crust and has five stable isotopes. The most common zinc ore is sphalerite
(zinc blende), a zinc sulfide mineral. The largest mineable amounts are found in
Australia, Asia, and the United States. Zinc production includes froth flotation of
the ore, roasting, and final extraction using electricity (electrowinning).”
• Source: Wikipedia
 Aluminum & Zinc
• “Zinc-aluminium (ZA) alloys are alloys whose main constituents are zinc and aluminium.
Other alloying elements include magnesium and copper. This type of alloy was originally
developed for gravity casting. Noranda, New Jersey Zinc Co. Ltd., St. Joe Mineral Co. and
ILZRO were the main companies that pioneered the ZA alloys between the 1950s and the
1970s. They were designed to compete with bronze, cast iron and aluminium using sand
and permanent mold casting methods. Distinguishing features of ZA alloys include high
as-cast strength, excellent bearing properties, as well as low energy requirements (for
melting).[1]

• ZA alloys make good bearings because their final composition includes hard eutectic
zinc-aluminium-copper particles embedded in a softer zinc-aluminium matrix. The hard
particles provide a low-friction bearing surface, while the softer material wears back to
provide space for lubricant to flow, similar to Babbitt metal.”

• Source: Wikipedia
Properties of various zinc aluminium alloys[1]
ZA8 ZA12 ZA27
Mechanical properties Sand cast Permanent mold Sand cast Permanent mold Sand cast Permanent mold

Ultimate tensile strength [ksi

38 (263) 32-37 (221-255) 40-46 (276-317) 45-50 (310-345) 58-64 (400-441) 45-47 (310-324)
(MPa)]

Yield strength - 0.2% offset

29 (200) 30 (206) 31 (214) 39 (269) 54 (372) 37 (255)
[ksi (MPa)]

Elongation [% in 2"] 1-2 1-2 1-3 1-3 3-6 8-11

Shear strength [ksi (MPa)] - 35 (241) 37 (255) - 42 (290) 33 (228)
Hardness [Brinell] 85 85-90 89-105 89-105 110-120 90-110
Impact strength [ft·lbf (J)] 156 (20) - 193 (25) - 353 (47) 433 (58)

Fatigue strength rotary bend in

- 7.5 (52) 15 (103) - 25 (172) 15 (103)
5x108 cycles [ksi (MPa)]

Compressive yield strength

29 (199) 31 (214) 33 (227) 34 (234) 48 (331) 37 (255)
0.1% offset [ksi (MPa)]

Modulus of elasticity [psi x

12.4 (85.5) 12.47 (85.5) 12.07 (82.7) 12.07 (82.7) 11.37 (77.9) 11.37 (77.9)
106 (MPa x 103)]

Poisson's ratio 0.29 0.29 0.30 0.30 0.32 0.32

Physical properties Sand cast Permanent mold Sand cast Permanent mold Sand cast Permanent mold
Density [lbm/in3 (g/cm3)] .227 (6.3) 0.227 (6.3) 0.218 (6.0) 0.218 (6.0) 0.181 (5.0) 0.181 (5.0)
Melting Range [°F (°C)] 707-759 (375-404) 707-759 (375-404) 710-810 (377-432) 710-810 (377-432) 708-903 (376-484) 708-903 (376-484)

Electrical Conductivity [S/m

1.61 (27.7) 1.61 (27.7) 1.64 (28.3) 1.64 (28.3) 1.72 (29.7) 1.72 (29.7)
(%IACS)]

Thermal Conductivity
66.3 (114.7) 66.3 (114.7) 67.1 (116.1) 67.1 (116.1) 72.5 (125.5) 72.5 (125.5)
[BTU/hr/ft2/°R (W/m/°K)]

CTE [68-212°F µin/in/°R (100-

12.9 (23.3) 12.9 (23.3) 13.4 (24.2) 13.4 (24.2) 14.4 (26.0) 14.4 (26.0)
200°C µm/mm/°K)]

Specific Heat [BTU/lbm/°R

.104 (435) .104 (435) .107 (448) .107 (448) .125 (523) .125 (523)
(J/kg/°K)]

Pattern of Die Shrinkage [in/ft

1/8 (10.4) 1/8 (10.4) 5/32 (13.0) 5/32 (13.0) 5/32 (13.0) 5/32 (13.0)
(mm/m)]
Chemical Specification (per ASTM) (% by Weight)

ZA12 ZA27
ZA8
Composition Ingot Casting Ingot Casting Ingot Casting
Al 8.2-8.8 8.0-8.8 10.8-11.5 10.5-11.5 25.5-28.0 25.0-28.0
Mg .020-.030 .015-.030 .020-.030 .015-.030 .012-.020 .010-.020
Cu 0.8-1.3 0.8-1.3 0.5-1.2 0.5-1.2 2.0-2.5 2.0-2.5
Fe (max) .065 .075 .065 .075 .072 .075
Pb (max) .005 .006 .005 .006 .005 .006
Cd .005 .006 .005 .006 .005 .006
Sn (max) .002 .003 .002 .003 .002 .003
Ni (other)x10 - - - - - -
Zn Bal Bal Bal Bal Bal Bal
Color Code
Blue Blue Orange Orange Purple Purple
ASTM B908
 Procedure
• Aluminum with 99.8% purity and zinc with 99.7% were obtained and cut into
multiple small chunks.
• Those chunks were then weighed and grouped together to prepare them to be
melted and alloyed.
• We decided to make five different samples. The two original samples, 100% Al and
100% Zn, one 80% Al and 20% Zn, one 50/50 Al-Zn and one 80% Zn 20% Al.
• Once all of the samples were weighed, we began melting the samples, followed by
pouring the melted samples sandcast mold to let them cool.
• Each sample was cut and set in bakelite powder and was compressed into a
cylindrical mold.
Aluminum

Zinc
Pure Zinc
Procedure
 Procedure

• Once the molds were ready, we polished each sample by sliding them in
sandpaper with different grits.
• After polishing the samples we successfully etched each of them, with the
exception of pure aluminum, by using a copper sulfate solution.
 Etching Solution

We used a deep etching technique for all of the five samples

The solution we used was CuSO4 in a concentration of 200 g per

liter ≈ 1.25 mol per liter
 Failures Succeses
• We were not able to etch the pure aluminum • We were able to observe the micro structure of
sample. most of our sample.
• Over etching of 80 % zinc hypereutectoid.
• Under etching of 100 % Zinc
Eutectic Diagram
 Al-Zn Phase Diagram

α = Al rich FCC phase

ß = Zn rich FCC phase
η = Zn rich HCP phase
L = Liquid Solution
20% Zn, 80% Al
50% Zn, 50% Al
80% Zn, 20% Al
100% Zn
 Sources

Aluminum - http://en.wikipedia.org/wiki/Aluminium
Zinc- http://en.wikipedia.org/wiki/Zinc
Zinc/Aluminum - http://en.wikipedia.org/wiki/Zinc_aluminium