The process is performed within 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 several cavities, each an exact inverse replica from the part or parts being produced. Due to the quick chill and rapid solidification which will take place when molten metal comes in contact 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 created by other methods.
Zinc pressure die castings, by way of example, are stronger than sand cast aluminum casting manufacturer, SAE 40 bronze, and sophistication 30 cast iron. Also, pressure die cast components produced making use of the ZA alloys are stronger than pressure die cast aluminum 380 alloy.
The name “ZAMAK” is an acronym from your German words that make up the alloys primary ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). As soon as 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); only the most desirable alloys (2-3-5-7) remain in use presently.
The name ZAMAK is undoubtedly an acronym through the German words that comprise the alloys main ingredients…
Zamak 2, a predecessor of your more traditionally used Zamak 3, offers the highest strength and hardness inside the 4% zinc, aluminum (Zamak) alloy family. Due to the 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 high 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 similar to aluminum alloys) for die cast products. It will, however, provide some interesting characteristics which can assist designers. Its creep performance is rated beyond one 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.
Nevertheless it does give up impact strength and due to this limitation Zamak 2 is just used as soon as the strength or hardness of Zamak 3 or 5 will not be sufficient for long-term end use. Zamak 2 may also be referred to as Kirksite and is also the only real alloy employed 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 offers the base composition for all the aluminum die casting alloys (96% zinc, 4% aluminum). Its superb physical and mechanical properties, excellent castability and long lasting dimensional stability give you the basis for its broad usage. The convenience it may be electroplated enhances the demand for this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. It is the “standard” by which other zinc alloys are
rated when it comes to die casting and it is, therefore, one of the most accessible alloy for die, casting sources.
Zamak 2, has got the highest strength and hardness from the 4% zinc, aluminum alloy family.
Most often through casting design procedures, a Zamak 3 pressure die casting can be created in order to meet service or functional requirements. When this is not the way it is, especially where strength is concerned, die casting parts is the next choice. Except for a nominal 1% copper addition, the chemistry of Zamak 5 resembles that from 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 the other alloys within the conventional group.
Zamak 5 is not really as ductile as several of the other alloys, one factor to consider when post casting operations like secondary bending, riveting, swaging or crimping will be required. As a result of 3’s wide availability, material specifiers often strength components by design modification as an alternative to Zamak 5. However, when an extra way of measuring tensile performance is needed,
Zamak 5 castings are recommended. The alloy is readily plated, finished and machined, and is comparable to Zamak 3.