The process is conducted in an automatic machine suitable to withstand high pressure.
The molten metal is pushed by way of a hydraulically actuated plunger in to a two-piece steel die containing a number of cavities, each an exact inverse replica of the part or parts being produced. As a result of quick chill and rapid solidification that can take place when molten metal comes in contact with the relatively cool steel side, and furthermore, as the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are often superior to castings produced by other methods.
Zinc pressure die castings, for instance, are stronger than sand cast aluminum casting manufacturer, SAE 40 bronze, and sophistication 30 cast iron. Also, pressure die cast components produced while using ZA alloys are stronger than pressure die cast aluminum 380 alloy.
The name “ZAMAK” is undoubtedly an acronym from your German words that comprise the alloys primary ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). As soon as the alloys were,developed 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); merely the most desirable alloys (2-3-5-7) stay in use presently.
The name ZAMAK is definitely an acronym in the German words that comprise the alloys primary ingredients…
Zamak 2, a predecessor of your more traditionally used Zamak 3, has the highest strength and hardness inside the 4% zinc, aluminum (Zamak) alloy family. Because of its relatively high copper content (3%), it really is approx. 25% stronger, as cast, than Zamak 3, and almost 10% stronger than Zamak 5, with higher hardness than both.
Our prime 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 will, however, provide some interesting characteristics which could assist designers. Its creep performance is rated greater than another Zamaks and #2 maintains higher tensile, strength and hardness levels after long term aging. Also, preliminary investigations suggest #2 is a good bearing material and may eliminate bushings and wear inserts in die designs.
But it does quit impact strength as a result of this limitation Zamak 2 is merely used once the strength or hardness of Zamak 3 or 5 are not sufficient for long-term end use. Zamak 2 may also be called Kirksite which is really the only alloy employed for gravity casting – mainly for metal forming dies or plastic injection molds.
ZAMAK 3 Of all of the zinc casting alloys, Zamak 3 is regarded as the popular, making up approx. 85% ofall zinc casting tonnage worldwide. They have the base composition for all of the die casting parts alloys (96% zinc, 4% aluminum). Its superb physical and mechanical properties, excellent castability and long lasting dimensional stability provide the basis for its broad usage. The ease it can be electroplated adds to the interest in this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. It is the “standard” through which other zinc alloys are
rated with regards to die casting and is, therefore, probably the most accessible alloy for die, casting sources.
Zamak 2, has got the highest strength and hardness from the 4% zinc, aluminum alloy family.
Generally through casting design procedures, a Zamak 3 pressure die casting can be made to satisfy service or functional requirements. When this may not be the case, especially where strength is involved, die casting parts will be the next choice. Except for a nominal 1% copper addition, the chemistry of Zamak 5 resembles that of Zamak 3. The composition modification brings about 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 just not as ductile as a few of the other alloys, a factor to think about when post casting operations like secondary bending, riveting, swaging or crimping are required. As a result of 3’s wide availability, material specifiers often strength components by design modification as opposed to Zamak 5. However, when an additional way of measuring tensile performance is essential,
Zamak 5 castings are recommended. The alloy is easily plated, finished and machined, and is similar to Zamak 3.