The process is conducted in an automatic machine suitable to withstand high pressure.
The molten metal is pushed by a hydraulically actuated plunger in to a two-piece steel die containing a number of cavities, each an exact inverse replica from the 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 also since the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are usually preferable over castings made by other methods.
Zinc pressure die castings, by way of example, are stronger than sand cast aluminum die casting parts, 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 surely an acronym in the German words that comprise the alloys primary ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). If 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); just 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 main ingredients…
Zamak 2, a predecessor of your more commonly used Zamak 3, has got the highest strength and hardness within the 4% zinc, aluminum (Zamak) alloy family. Simply because of 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.
Our prime 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 much like aluminum alloys) for die cast products. It can, however, provide some interesting characteristics which could 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 a good bearing material and may eliminate bushings and wear inserts in die designs.
However it does surrender impact strength and due to this limitation Zamak 2 is just used if the strength or hardness of Zamak 3 or 5 are not sufficient for long-term end use. Zamak 2 is oftentimes known as Kirksite and is the only real alloy used for gravity casting – mainly for metal forming dies or plastic injection molds.
ZAMAK 3 Of all the zinc casting alloys, Zamak 3 is regarded as the traditionally used, making up approx. 85% ofall zinc casting tonnage worldwide. It has 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 benefit it could be electroplated increases the interest in this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. This is the “standard” where other zinc alloys are
rated with regards to die casting and is, therefore, one of the most easily available 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 done to satisfy service or functional requirements. When this is not the way it is, especially where strength is involved, Zinc die casting will be the next choice. Except for a nominal 1% copper addition, the chemistry of Zamak 5 is comparable to that from Zamak 3. The composition modification results in higher tensile strength and increased hardness, but sacrifices elongation. Zamak 5 has significantly better creep resistance in comparison to the other alloys inside the conventional group.
Zamak 5 is not really as ductile as several of the other alloys, a factor to consider when post casting operations for example secondary bending, riveting, swaging or crimping are needed. As a consequence 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 easily plated, finished and machined, and resembles Zamak 3.