The process is carried out in a automatic machine suitable to withstand high pressure.
The molten metal is pushed by a hydraulically actuated plunger right into a two-piece steel die containing several cavities, each an exact inverse replica from the part or parts being produced. Because of the quick chill and rapid solidification which will take 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 preferable over castings produced by other methods.
Zinc pressure die castings, as an example, are stronger than sand cast aluminum die casting parts, SAE 40 bronze, and sophistication 30 cast iron. Also, pressure die cast components produced utilizing the ZA alloys are stronger than pressure die cast aluminum 380 alloy.
The name “ZAMAK” is an acronym from the German words that make up the alloys main ingredients: Z (zinc) A (aluminum) M (magnesium) and K (copper). If the alloys were,developed 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); only the most desirable alloys (2-3-5-7) remain in use presently.
The name ZAMAK is definitely an acronym from your German words that comprise the alloys main ingredients…
Zamak 2, a predecessor in the more traditionally used Zamak 3, has got the highest strength and hardness from 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, 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 comparable to aluminum alloys) for die cast products. It will, however, provide some interesting characteristics which might assist designers. Its creep performance is rated more than one other Zamaks and #2 maintains higher tensile, strength and hardness levels after long term aging. Also, preliminary investigations suggest #2 is an excellent bearing material and may eliminate bushings and wear inserts in die designs.
But it does stop trying impact strength and because of this limitation Zamak 2 is simply used once the strength or hardness of Zamak 3 or 5 usually are not sufficient for long-term end use. Zamak 2 might be known as Kirksite and it is the only 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 regarded as the commonly used, accounting for 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 give you the grounds for its broad usage. The convenience it may be electroplated enhances the demand for this alloy, with excellent finishing characteristics 21dexupky plating, painting, and chromate treatments. It will be the “standard” where other zinc alloys are
rated when it comes to die casting which is, therefore, probably the most easily available alloy for die, casting sources.
Zamak 2, offers the highest strength and hardness within 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 way it is, especially where strength is concerned, die casting parts is definitely the next choice. Aside from a nominal 1% copper addition, the chemistry of Zamak 5 is similar to that of Zamak 3. The composition modification brings about higher tensile strength and increased hardness, but sacrifices elongation. Zamak 5 has significantly better creep resistance than the other alloys inside the conventional group.
Zamak 5 is not really as ductile as a few of the other alloys, an issue to consider when post casting operations for example secondary bending, riveting, swaging or crimping are essential. As a result of 3’s wide availability, material specifiers often strength components by design modification instead of Zamak 5. However, when another way of measuring tensile performance is essential,
Zamak 5 castings are recommended. The alloy is easily plated, finished and machined, and is comparable to Zamak 3.