The process is carried out within an automatic machine suitable to stand up to high-pressure.
The molten metal is pushed with a hydraulically actuated plunger in a two-piece steel die containing one or more cavities, each a precise inverse replica from the part or parts being produced. As a result of quick chill and rapid solidification that can take place when molten metal comes in touch with the relatively cool steel side, and since the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are often better than castings created by other methods.
Zinc pressure die castings, for example, are stronger than sand cast aluminum casting manufacturer, SAE 40 bronze, and sophistication 30 cast iron. Also, pressure die cast components produced using the ZA alloys are stronger than pressure die cast aluminum 380 alloy.
The name “ZAMAK” is an acronym from your German words that define the alloys primary ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). If the alloys were,created in the 1920s the 1st useable material was designated Zamak #1. With every subsequent iteration, the designations increased sequentially (1-2-3-4-5-6-7); merely the most desirable alloys (2-3-5-7) stay in use presently.
The name ZAMAK is an acronym from the German words that define the alloys primary ingredients…
Zamak 2, a predecessor of your more commonly used Zamak 3, has the highest strength and hardness inside the 4% zinc, aluminum (Zamak) alloy family. Due to the relatively high copper content (3%), it can be approx. 25% stronger, as cast, than Zamak 3, and almost 10% stronger than Zamak 5, with higher hardness than both.
The high copper content, however, leads to property changes upon long lasting aging. These changes include slight dimensional growth (.0014in/in after 20yrs), lower elongation and reduced impact performance (to levels just like aluminum alloys) for die cast products. It can, however, provide some interesting characteristics which might assist designers. Its creep performance is rated greater than other Zamaks and #2 maintains higher tensile, strength and hardness levels after long lasting aging. Also, preliminary investigations suggest #2 is a great bearing material and may eliminate bushings and wear inserts in die designs.
Nevertheless it does stop trying impact strength as a result of this limitation Zamak 2 is only used once the strength or hardness of Zamak 3 or 5 will not be sufficient for too long-term end use. Zamak 2 is sometimes called Kirksite and it is the only real alloy employed for gravity casting – mainly for metal forming dies or plastic injection molds.
ZAMAK 3 Of all zinc casting alloys, Zamak 3 is considered the most commonly used, comprising approx. 85% ofall zinc casting tonnage worldwide. It has the base composition for all the water proof aluminum enclosure alloys (96% zinc, 4% aluminum). Its superb physical and mechanical properties, excellent castability and long-term dimensional stability provide you with the basis for its broad usage. The benefit it may be electroplated adds to the rise in popularity of this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. It will be the “standard” in which other zinc alloys are
rated with regards to die casting and is, therefore, one of the most easily available alloy for die, casting sources.
Zamak 2, provides the highest strength and hardness inside the 4% zinc, aluminum alloy family.
Usually through casting design procedures, a Zamak 3 pressure die casting can be created to meet service or functional requirements. When this is not the truth, especially where strength is concerned, Zinc die casting may be the next choice. Aside from a nominal 1% copper addition, the chemistry of Zamak 5 resembles that relating to Zamak 3. The composition modification contributes to higher tensile strength and increased hardness, but sacrifices elongation. Zamak 5 has significantly better creep resistance compared to other alloys from the conventional group.
Zamak 5 is just not as ductile as several of the other alloys, a factor to think about when post casting operations including secondary bending, riveting, swaging or crimping are needed. Due to 3’s wide availability, material specifiers often strength components by design modification rather than Zamak 5. However, when an additional way of measuring tensile performance is essential,
Zamak 5 castings are recommended. The alloy is readily plated, finished and machined, and is comparable to Zamak 3.