The procedure is carried out in an automatic machine suitable to resist high pressure.
The molten metal is pushed with a hydraulically actuated plunger right into a two-piece steel die containing several cavities, each a precise inverse replica of your part or parts being produced. As a result of quick chill and rapid solidification that takes 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 usually superior to castings manufactured by other methods.
Zinc pressure die castings, for instance, are stronger than sand cast aluminum die casting parts, 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 an acronym from the German words that make up the alloys primary ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). When 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); only the most desirable alloys (2-3-5-7) stay in use presently.
The name ZAMAK is definitely an acronym from the German words that define the alloys primary ingredients…
Zamak 2, a predecessor from the more commonly used Zamak 3, offers the highest strength and hardness from the 4% zinc, aluminum (Zamak) alloy family. Simply 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.
The top copper content, however, brings about property changes upon long lasting 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 can do, however, provide some interesting characteristics which could assist designers. Its creep performance is rated more than other Zamaks and #2 maintains higher tensile, strength and hardness levels after long term aging. Also, preliminary investigations suggest #2 is a great bearing material and could eliminate bushings and wear inserts in die designs.
But it does quit impact strength and due to this limitation Zamak 2 is merely used once the strength or hardness of Zamak 3 or 5 are certainly not sufficient for too long-term end use. Zamak 2 might be called Kirksite which is 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 considered the most widely used, accounting for approx. 85% ofall zinc casting tonnage worldwide. They have the base composition for those aluminum die casting alloys (96% zinc, 4% aluminum). Its superb physical and mechanical properties, excellent castability and long term dimensional stability supply the grounds for its broad usage. The benefit it might be electroplated adds to the rise in popularity of this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. It will be the “standard” where other zinc alloys are
rated with regards to die casting and it is, therefore, by far the most widely available alloy for die, casting sources.
Zamak 2, offers 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 done to meet service or functional requirements. When this is not the truth, especially where strength is concerned, Zinc die casting may be the next choice. With the exception of a nominal 1% copper addition, the chemistry of Zamak 5 is similar to those 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 inside the conventional group.
Zamak 5 is just not as ductile as a few of the other alloys, an aspect to take into account when post casting operations including 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 essential,
Zamak 5 castings are recommended. The alloy is readily plated, finished and machined, and resembles Zamak 3.