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

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.