The procedure is conducted within an automatic machine suitable to resist high pressure.
The molten metal is pushed from a hydraulically actuated plunger right into a two-piece steel die containing several cavities, each a precise 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 since the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are typically 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 using the ZA alloys are stronger than pressure die cast aluminum 380 alloy.
The name “ZAMAK” is undoubtedly an acronym from your German words that define the alloys main ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). Once 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); merely the most desirable alloys (2-3-5-7) remain in use presently.
The name ZAMAK is definitely an acronym from your German words that define the alloys primary ingredients…
Zamak 2, a predecessor of your more commonly used Zamak 3, provides the highest strength and hardness within 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.
The top copper content, however, brings about property changes upon lasting 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 can do, however, provide some interesting characteristics which can assist designers. Its creep performance is rated greater 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 may even eliminate bushings and wear inserts in die designs.
But it really does stop trying impact strength as a result of this limitation Zamak 2 is only used when the strength or hardness of Zamak 3 or 5 are not sufficient for long-term end use. Zamak 2 is sometimes called Kirksite and is also the sole 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 easily the most widely used, making up approx. 85% ofall zinc casting tonnage worldwide. It has the base composition for all of the water proof aluminum enclosure 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 may be electroplated adds to the popularity of this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. It is the “standard” in which other zinc alloys are
rated regarding die casting and is, therefore, one of the most easily available alloy for die, casting sources.
Zamak 2, offers the highest strength and hardness within the 4% zinc, aluminum alloy family.
Usually through casting design procedures, a Zamak 3 pressure die casting can be made to satisfy service or functional requirements. When this is simply not the situation, especially where strength is involved, Zinc die casting is definitely the next choice. With the exception of a nominal 1% copper addition, the chemistry of Zamak 5 is comparable to that relating to Zamak 3. The composition modification contributes to higher tensile strength and increased hardness, but sacrifices elongation. Zamak 5 has significantly better creep resistance compared to other alloys inside the conventional group.
Zamak 5 will not be as ductile as a number of the other alloys, an issue to take into account when post casting operations for example secondary bending, riveting, swaging or crimping will be required. Because of 3’s wide availability, material specifiers often strength components by design modification instead of Zamak 5. However, when another measure of tensile performance is required,
Zamak 5 castings are recommended. The alloy is easily plated, finished and machined, and is comparable to Zamak 3.