The process is conducted inside an automatic machine suitable to resist high pressure.
The molten metal is pushed by way of a hydraulically actuated plunger right into a two-piece steel die containing one or more cavities, each an exact inverse replica of your 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 typically preferable over castings created by other methods.
Zinc pressure die castings, by way of example, are stronger than sand cast CNC precision machining, SAE 40 bronze, and sophistication 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 surely an acronym through the 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 first useable material was designated Zamak #1. With each subsequent iteration, the designations increased sequentially (1-2-3-4-5-6-7); just the most desirable alloys (2-3-5-7) stay in use presently.
The name ZAMAK is surely an acronym through the German words that comprise the alloys main ingredients…
Zamak 2, a predecessor of the more traditionally used Zamak 3, offers the highest strength and hardness within the 4% zinc, aluminum (Zamak) alloy family. Simply 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, brings about property changes upon long-term aging. These changes include slight dimensional growth (.0014in/in after 20yrs), lower elongation and reduced impact performance (to levels similar to aluminum alloys) for die cast products. It can do, however, provide some interesting characteristics which may assist designers. Its creep performance is rated higher than the other Zamaks and #2 maintains higher tensile, strength and hardness levels after long term aging. Also, preliminary investigations suggest #2 is an excellent bearing material and could eliminate bushings and wear inserts in die designs.
But it really does quit impact strength and due to this limitation Zamak 2 is just used as soon as the strength or hardness of Zamak 3 or 5 usually are not sufficient for very long-term end use. Zamak 2 is sometimes called Kirksite and is the sole alloy used for gravity casting – mainly for metal forming dies or plastic injection molds.
ZAMAK 3 Of all zinc casting alloys, Zamak 3 is regarded as the widely used, making up approx. 85% ofall zinc casting tonnage worldwide. It provides the base composition for 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 basis for its broad usage. The benefit it can be electroplated enhances the rise in popularity of this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. This is the “standard” through which other zinc alloys are
rated with regards to die casting and is also, therefore, one of the most widely available alloy for die, casting sources.
Zamak 2, has the highest strength and hardness in the 4% zinc, aluminum alloy family.
Generally through casting design procedures, a Zamak 3 pressure die casting can be created to meet service or functional requirements. When this may not be the situation, especially where strength is concerned, Zinc die casting is definitely the next choice. Aside from a nominal 1% copper addition, the chemistry of Zamak 5 resembles that relating to Zamak 3. The composition modification results in higher tensile strength and increased hardness, but sacrifices elongation. Zamak 5 has significantly better creep resistance compared to the other alloys from the conventional group.
Zamak 5 is not really as ductile as several of the other alloys, an aspect to take into consideration when post casting operations including secondary bending, riveting, swaging or crimping are needed. As a result of 3’s wide availability, material specifiers often strength components by design modification as an alternative to Zamak 5. However, when another measure of tensile performance is needed,
Zamak 5 castings are recommended. The alloy is readily plated, finished and machined, and resembles Zamak 3.