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Zinc die casting products and metal casting processes continue to evolve for the benefit of end users. Through cooperative global research programs continuous improvements are still being made to the broad range of excellent mechanical properties, easy castability and the wide choice of finishes available for zinc die castings. Recent advances will be highlighted with case histories specific to automotive applications.

Alloy 3, Alloy 5, ACuZinc 5, and ZA-8 were tested at five temperatures between −40 C and room temperature to determine impact properties. Izod impact energy data was obtained in accordance with ASTM D256. Unlike ASTM E23, these samples were tested with a milled notch in order to compare with plastic samples. In addition, flexural data was obtained for design use. Fatigue stress-life (S-N) curves and fatigue limits of die cast zinc Alloy 2, Alloy 3, Alloy 5, ACuZinc 5, and ZA-8 were determined using the rotating bend test. Fatigue limits for Alloy 3, Alloy 5, and ACuZinc 5 appeared to be higher and the fatigue limit for ZA-8 appeared to be lower than the values reported in the literature. The improvement in properties for Alloy 3, Alloy 5 and ACuZinc 5 is related to the presence of the die cast skin.