The process is carried out in an automatic machine suitable to withstand high-pressure.
The molten metal is pushed from a hydraulically actuated plunger right into a two-piece steel die containing more than one cavities, each an exact inverse replica of your part or parts being produced. Because of the quick chill and rapid solidification that can take place when molten metal comes in touch with the relatively cool steel side, and because the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are typically better than castings made by other methods.
Zinc pressure die castings, for example, are stronger than sand cast CNC precision machining, SAE 40 bronze, and class 30 cast iron. Also, pressure die cast components produced utilizing the ZA alloys are stronger than pressure die cast aluminum 380 alloy.
The name “ZAMAK” is an acronym from the German words that define the alloys main ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). When 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); simply the most desirable alloys (2-3-5-7) stay in use presently.
The name ZAMAK is surely an acronym from your German words that make up the alloys primary ingredients…
Zamak 2, a predecessor from the more widely used Zamak 3, offers the highest strength and hardness inside the 4% zinc, aluminum (Zamak) alloy family. Because of its relatively high copper content (3%), it is approx. 25% stronger, as cast, than Zamak 3, and almost 10% stronger than Zamak 5, with higher hardness than both.
The top copper content, however, results in property changes upon lasting aging. These changes include slight dimensional growth (.0014in/in after 20yrs), lower elongation and reduced impact performance (to levels much like aluminum alloys) for die cast products. It will, however, provide some interesting characteristics which can assist designers. Its creep performance is rated beyond other Zamaks and #2 maintains higher tensile, strength and hardness levels after lasting aging. Also, preliminary investigations suggest #2 is a superb bearing material and could eliminate bushings and wear inserts in die designs.
But it really does give up impact strength and because of this limitation Zamak 2 is only used when the strength or hardness of Zamak 3 or 5 are not sufficient for too long-term end use. Zamak 2 is sometimes termed as Kirksite which is really the only alloy utilized for gravity casting – mainly for metal forming dies or plastic injection molds.
ZAMAK 3 Of the zinc casting alloys, Zamak 3 is regarded as the popular, comprising approx. 85% ofall zinc casting tonnage worldwide. It provides the base composition for all of the aluminum die casting alloys (96% zinc, 4% aluminum). Its superb physical and mechanical properties, excellent castability and long term dimensional stability give you the grounds for its broad usage. The ease it could be electroplated enhances the rise in popularity of this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. It is the “standard” by which other zinc alloys are
rated with regards to die casting which is, therefore, the most widely available alloy for die, casting sources.
Zamak 2, offers the highest strength and hardness in the 4% zinc, aluminum alloy family.
Most often through casting design procedures, a Zamak 3 pressure die casting can be done to satisfy service or functional requirements. When this is simply not the way it is, especially where strength is involved, die casting parts is definitely the next choice. With the exception of a nominal 1% copper addition, the chemistry of Zamak 5 is similar to that relating to Zamak 3. The composition modification leads to higher tensile strength and increased hardness, but sacrifices elongation. Zamak 5 has significantly better creep resistance than the other alloys in the conventional group.
Zamak 5 will not be as ductile as a number of the other alloys, an aspect to take into consideration when post casting operations like secondary bending, riveting, swaging or crimping are needed. As a consequence of 3’s wide availability, material specifiers often strength components by design modification as an alternative to Zamak 5. However, when an added measure of tensile performance is needed,
Zamak 5 castings are recommended. The alloy is easily plated, finished and machined, and is comparable to Zamak 3.