Work

Preliminary Investigations into Internally Coated Fittings Made from ZnAl15Cu1Mg (ZEP1510)

Year: 2026

Type: article

Abstract: Stricter drinking water regulations intensify the need to replace leaded brasses in fittings. This work reports preliminary results on internally coated fittings using the wrought zinc alloy ZnAl15Cu1Mg (ZEP1510). A straight-tube Model Geometry 1 was lined internally with HDPE by gas-assisted injection molding, achieving a continuous barrier of 1.55–1.70 mm without altering the external envelope. A press-type T-fitting (32–32–32) was defined as Model Geometry 2 to benchmark forgeability; process layout (FEM) and warm-forging trials are summarized. Recycling relevance was addressed via a partial-melt (drip-off) route, which removed a substantial polymer fraction but left measurable residues. A production-cycle PCF from material production to finished tee indicates 3.156 kg CO2e for ZEP1510 vs. 5.385 kg CO2e (CuZn40Pb2) and 6.301 kg CO2e (CuZn21Si3), i.e., 41.85% and 50.06% savings. These findings establish manufacturability, indicate recycling feasibility, and quantify a CO2 advantage, outlining the next steps toward lining complex geometries and drinking water compliance.

Source: Metals

DOI: 10.3390/met16040372