The procedure is performed in an automatic machine suitable to resist high pressure.
The molten metal is pushed by way of a hydraulically actuated plunger right into a two-piece steel die containing more than one cavities, each an exact inverse replica of your part or parts being produced. Due to quick chill and rapid solidification which takes place when molten metal comes in contact with the relatively cool steel side, and furthermore, as the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are often superior to castings made by other methods.
Zinc pressure die castings, for example, are stronger than sand cast CNC precision machining, 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 definitely an acronym through the 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 initial useable material was designated Zamak #1. With each subsequent iteration, the designations increased sequentially (1-2-3-4-5-6-7); just 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 main ingredients…
Zamak 2, a predecessor in the more widely used Zamak 3, offers the highest strength and hardness in the 4% zinc, aluminum (Zamak) alloy family. 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.
Our prime copper content, however, contributes to property changes upon long-term 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 higher than other Zamaks and #2 maintains higher tensile, strength and hardness levels after 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 and because of this limitation Zamak 2 is only used once the strength or hardness of Zamak 3 or 5 will not be sufficient for too long-term end use. Zamak 2 is oftentimes known as Kirksite and is also the sole alloy utilized for gravity casting – mainly for metal forming dies or plastic injection molds.
ZAMAK 3 Of all of the zinc casting alloys, Zamak 3 is considered the most widely used, making up approx. 85% ofall zinc casting tonnage worldwide. They have 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 ease it might be electroplated enhances the rise in popularity of this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. This is the “standard” in which other zinc alloys are
rated with regards to die casting and is also, therefore, by far the most easily available alloy for die, casting sources.
Zamak 2, has got the highest strength and hardness inside the 4% zinc, aluminum alloy family.
In most cases through casting design procedures, a Zamak 3 pressure die casting can be created in order to meet service or functional requirements. When this may not be the truth, especially where strength is concerned, die casting parts is 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 compared to other alloys from the conventional group.
Zamak 5 is not really as ductile as a number of the other alloys, an aspect to consider when post casting operations for example secondary bending, riveting, swaging or crimping are essential. Due to 3’s wide availability, material specifiers often strength components by design modification as an alternative to Zamak 5. However, when an extra measure of tensile performance is required,
Zamak 5 castings are recommended. The alloy is easily plated, finished and machined, and is similar to Zamak 3.