The process is conducted in a 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 also since the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are generally better than castings produced 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 using the ZA alloys are stronger than pressure die cast aluminum 380 alloy.
The name “ZAMAK” is undoubtedly an acronym in the German words that comprise the alloys main 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 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 an acronym through the German words that define the alloys primary ingredients…
Zamak 2, a predecessor in the more widely used Zamak 3, provides the highest strength and hardness in the 4% zinc, aluminum (Zamak) alloy family. Due to its 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, results in property changes upon long-term aging. These changes include slight dimensional growth (.0014in/in after 20yrs), lower elongation and reduced impact performance (to levels comparable to aluminum alloys) for die cast products. It does, 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 lasting aging. Also, preliminary investigations suggest #2 is a great 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 merely used as soon as the strength or hardness of Zamak 3 or 5 usually are not sufficient for long-term end use. Zamak 2 may also be known as Kirksite and is the sole alloy used 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, accounting for approx. 85% ofall zinc casting tonnage worldwide. It has the base composition for those 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 convenience it might be electroplated boosts the rise in popularity of this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. This is basically the “standard” through which other zinc alloys are
rated regarding die casting and it is, therefore, probably the most widely accessible alloy for die, casting sources.
Zamak 2, has got 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 produced to satisfy service or functional requirements. When this may not be the situation, especially where strength is concerned, die casting parts is the next choice. With the exception of 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 not really as ductile as a few of the other alloys, an issue to take into account 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 instead of Zamak 5. However, when an extra 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.