The process is carried out inside an automatic machine suitable to stand up to high pressure.
The molten metal is pushed from a hydraulically actuated plunger into a two-piece steel die containing a number of cavities, each an exact inverse replica from the part or parts being produced. Because of the quick chill and rapid solidification that can take place when molten metal comes in contact with the relatively cool steel side, and also since the fine metallurgical grain structure that results, the mechanical properties of pressure die castings are typically preferable over 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 surely an acronym from the German words that make up the alloys primary ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). Once the alloys were,created in the 1920s the initial useable material was designated Zamak #1. With every subsequent iteration, the designations increased sequentially (1-2-3-4-5-6-7); simply the most desirable alloys (2-3-5-7) stay in use presently.
The name ZAMAK is undoubtedly an acronym from the German words that comprise the alloys main ingredients…
Zamak 2, a predecessor of your more popular Zamak 3, has got 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.
The top copper content, however, leads 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 comparable to aluminum alloys) for die cast products. It will, however, provide some interesting characteristics which could assist designers. Its creep performance is rated more than the 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.
Nevertheless it does quit impact strength and due to this limitation Zamak 2 is just used as soon as the strength or hardness of Zamak 3 or 5 are certainly not sufficient for long-term end use. Zamak 2 may also be called Kirksite and it is the only real alloy useful for gravity casting – mainly for metal forming dies or plastic injection molds.
ZAMAK 3 Of all the zinc casting alloys, Zamak 3 is considered the most popular, comprising approx. 85% ofall zinc casting tonnage worldwide. It has the base composition for those water proof aluminum enclosure alloys (96% zinc, 4% aluminum). Its superb physical and mechanical properties, excellent castability and long term dimensional stability supply the basis for its broad usage. The convenience it could be electroplated boosts the demand for this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. This is the “standard” in which other zinc alloys are
rated in terms of die casting and is also, therefore, one of the most widely accessible alloy for die, casting sources.
Zamak 2, offers the highest strength and hardness within the 4% zinc, aluminum alloy family.
Most often through casting design procedures, a Zamak 3 pressure die casting can be produced to satisfy service or functional requirements. When this is simply not the situation, especially where strength is involved, Zinc die casting is 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 leads to 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 will not be as ductile as some of the other alloys, an aspect to think about when post casting operations including secondary bending, riveting, swaging or crimping will be required. Because of 3’s wide availability, material specifiers often strength components by design modification rather than Zamak 5. However, when another way of measuring tensile performance is required,
Zamak 5 castings are recommended. The alloy is readily plated, finished and machined, and is comparable to Zamak 3.