The procedure is carried out in an automatic machine suitable to withstand high-pressure.
The molten metal is pushed from a hydraulically actuated plunger into a two-piece steel die containing one or more cavities, each a precise inverse replica in the part or parts being produced. Due to quick chill and rapid solidification which will 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 better than castings manufactured by other methods.
Zinc pressure die castings, by way of example, are stronger than sand cast aluminum casting manufacturer, SAE 40 bronze, and class 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 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,developed in the 1920s the very first 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 surely an acronym from your German words that comprise the alloys primary ingredients…
Zamak 2, a predecessor in the more commonly used Zamak 3, provides the highest strength and hardness inside the 4% zinc, aluminum (Zamak) alloy family. Due to the relatively high copper content (3%), it is actually 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, leads to property changes upon long lasting aging. These changes include slight dimensional growth (.0014in/in after 20yrs), lower elongation and reduced impact performance (to levels just like aluminum alloys) for die cast products. It will, however, provide some interesting characteristics which can assist designers. Its creep performance is rated higher than the other Zamaks and #2 maintains higher tensile, strength and hardness levels after long lasting aging. Also, preliminary investigations suggest #2 is an excellent 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 when the strength or hardness of Zamak 3 or 5 are not sufficient for very long-term end use. Zamak 2 might be called Kirksite which is the only real alloy used for gravity casting – mainly for metal forming dies or plastic injection molds.
ZAMAK 3 Of all of the zinc casting alloys, Zamak 3 is the most popular, comprising approx. 85% ofall zinc casting tonnage worldwide. They have the base composition for all of the 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 ease it could be electroplated enhances the interest in this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. It is the “standard” in which other zinc alloys are
rated with regards to die casting and it is, therefore, the most accessible alloy for die, casting sources.
Zamak 2, provides the highest strength and hardness inside the 4% zinc, aluminum alloy family.
Generally through casting design procedures, a Zamak 3 pressure die casting can be created to fulfill service or functional requirements. When this may not be the case, especially where strength is concerned, CNC precision machining will be the next choice. Apart from a nominal 1% copper addition, the chemistry of Zamak 5 resembles that relating to Zamak 3. The composition modification results in higher tensile strength and increased hardness, but sacrifices elongation. Zamak 5 has significantly better creep resistance than the other alloys in the conventional group.
Zamak 5 is just not as ductile as several of the other alloys, an aspect to think about when post casting operations such as secondary bending, riveting, swaging or crimping are required. Due to 3’s wide availability, material specifiers often strength components by design modification as an alternative to Zamak 5. However, when an added way of measuring tensile performance is needed,
Zamak 5 castings are recommended. The alloy is readily plated, finished and machined, and is similar to Zamak 3.