Zamak Die casting is produced by the die casting process, which is an excellent way to create complex metal parts. The die casting process primarily works with a limited range of metals. Some popular metals are zinc, copper, aluminum, and magnesium. Among these, zinc holds significant importance and is widely used in various applications. ZAMAK die-casting alloy is the most pervasive zinc alloy.

Fundición a presión ZAMAK has different types: HPDC, LPDC, and gravity. Since ZAMAK has a low melting point, the HPDC method is mainly preferred, and we normally call this zamak die casting machine a hot chamber die casting machine; on the other hand, an aluminum die casting machine is a cold chamber die casting machine.

This article highlights what die-casting ZAMAK alloys are and their benefits. Furthermore, it delves into the process by which foundries create ZAMAK die-casting parts.

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Presentación de la aleación ZAMAK de fundición a presión

ZAMAK son las siglas de Zinc, Aluminio, Magnesio y Cobre (Kupfer). Es una denominación alemana de aleación de metales. El zinc es el material base, y oscila entre 94% y 96%.

ZAMAK alloys offer benefits that make these alloys suitable for die-casting. In short, they provide a low melting point, high fluidity, and a strength-to-weight ratio. They also offer additional benefits that you will learn about in the following sections.

Las aleaciones ZAMAK se utilizan ampliamente en fundiciones a presión. Las piezas de aleación ZAMAK fundidas a presión prevalecen en muchas aplicaciones. Estas piezas de fundición son cruciales, desde piezas de automóviles hasta componentes electrónicos y de ferretería. Además, son 100% reciclables.

Moreover, they usually come with a wide range of surface finishes. Because they provide good adhesion quality, you can apply a variety of surface treatments to ZAMAK parts. Because of this, ZAMAK alloy parts can offer a premium look. Moreover, they are widely used in decorative applications.

Diferentes tipos de fundición a presión ZAMAK Alloys

Die Casting ZAMAK alloys have many types or grades. This diversity typically arises due to the need for different situations. For example, some situations require high strength, while others require good flexibility.

fundición a presión de zamak

Die-cast ZAMAK 3 and ZAMAK 5 die castings are two popular zinc grades.  ZAMAK 3 die casting offers a perfect balance of strength and flexibility. On the other hand, ZAMAK 5 die casting gives more strength and hardness. Both alloys are widely used in various applications.

También puede encontrar otras aleaciones ZAMAK. La siguiente tabla resume las diferentes aleaciones ZAMAK. La tabla destaca su composición, ventajas y uso.

Cuadro 1 Tabla de composición de aleaciones ZAMAK para fundición a presión

Cuadro 2 ZAMAK Die Casting Alloy Summerize Mesa

¿Por qué utilizar aleaciones ZAMAK de fundición a presión?

Hay muchas razones para utilizar las aleaciones ZAMAK. Debido a sus ventajas, las aleaciones ZAMAK a veces sustituyen a la fundición de aluminio. Esta sección habla principalmente de las ventajas de la fundición a presión de aleaciones ZAMAK.

Reason #1: High Fluidity

Fluidity refers to how easily molten metal flows into a die casting mold during casting. High fluidity allows the ZAMAC alloy to fill the die cavity with ease. Because of this feature, you can create even more complex designs. This feature allows the molten metal to reach every corner of the design, ensuring high fluidity. As a result, you can get better-surfaced, finished die-casting parts.

Reason #2: toughness and high rigidity

Las aleaciones ZAMAK de fundición a presión son duras y resistentes a la deformación. Por ello, estas aleaciones son duraderas y funcionan bien en operaciones continuas. ZAMAK 2 y 5 ofrecen una gran rigidez y tenacidad.

Reason #3: High Strength-To-Weight Ratio

Die-casting ZAMAK alloys are both robust and lightweight. Aluminum offers a stronger strength-to-weight ratio than ZAMAK. Note that aluminum’s tensile strength is 310 MPa, while ZAMAK’s is 280 MPa. However, ZAMAK die-casting parts are also widely used in various applications.

Reason #4: Low Melting Point

The melting point of die-casting ZAMAK alloys ranges from 380 to 420 degrees Celsius (except for ZAMAK 2). It means you can quickly melt and solidify.

There are some benefits of a low melting point:

1. It reduces the energy cost.
2. It makes the production faster.
3. It also simplifies the production.
4. It ensures fewer defects in casting metal parts.

Reason #5: Excellent Adhesion

Excellent adhesion means that ZAMAK die-casting alloys effectively bond with coatings. You can do a wide range of surface treatments. As a result, electronic plating can enhance the appearance of your final part significantly. You can give it a premium look as per your design. Moreover, it enhances the corrosion resistance of your metal parts.

Reason #6: Excellent Wearing and Bearing Properties

Die-casting ZAMAK alloys resist wear and effectively endure friction. ZAMAK parts typically maintain quality and functionality. They remain intact even under continuous stress.

Esta característica es fundamental en la fundición a presión. Reduce los costes de sustitución, algo crucial para piezas móviles como engranajes y palancas.

Reason #7: 100% recyclable and environmentally friendly.

ZAMAK die-casting alloys are 100% recyclable. You can completely melt and reuse it. It won’t waste any material, and you can use all scrap.

Esta característica suele reducir los costes de materia prima y garantiza la ausencia de impacto medioambiental. Tenga en cuenta que las aleaciones ZAMAK recicladas conservan la misma calidad que el material nuevo.

Reason #8: Cost-Effective

Las aleaciones de fundición a presión ZAMAK son soluciones rentables. Suelen costar menos que el aluminio. Según las tendencias del mercado 2024, los metales ZAMAK son ligeramente más caros que el aluminio. Sin embargo, las aleaciones ZAMAK son más baratas que otros metales y sus aleaciones.

¿Cuáles son las limitaciones de la fundición inyectada de la aleación ZAMAK?

ZAMAK die-casting metals offer numerous benefits, but they also present certain challenges.

1. These alloys have a low melting point. When used at varying temperatures, their properties change dramatically. However, they become fragile when the temperature rises too high.
2. When ZAMAK alloys are mixed with tin or lead, they lose some of their flexibility and corrosion resistance.
3. Some ZAMAK alloys may not be suitable for lightweight applications.

¿Qué es la fundición a presión ZAMAK?

Z

AMAK die casting is a popular metal casting method. This method forces molten zamak alloy into a die or mold cavity under high pressure. The die or mold is generally made of high-quality tool steel. For each type of shape, there are specific dies; to proceed with the zamak die casting process, you need to have a hot chamber die casting machine.

Typically, the hot chamber die casting machine divides the material into two halves: one stationary and the other movable. When these halves are closed, the method uses an injection chamber to inject the molten metal into them. Once the metal is solidified, operators take the casting parts out using ejector pins. Since you are using ZAMAK alloys, this process is known as ZAMAK die casting.

La aleación ZAMAK es adecuada para la fundición a presión HPDC, LPDC y por gravedad. Ya conoce sus ventajas y limitaciones.

The ZAMAK die casting process

fundición a presión ZAMAK, o zinc die casting, is also a process similar to that of other alloy materials such as aluminum ormagnesium.  Foundries must ensure precise and efficient production to ensure high-quality outcomes.From designing to surface treatment, each step needs professional work.   Here is a step-by-step guide to the ZAMAK die-casting process.

Step #1: Design and Making of Die

ZAMAK die casting begins by designing the final part and mold or die. This step is of utmost importance as it largely determines the outcome.

En primer lugar, los ingenieros de la fundición crean el modelo 3D de la pieza final que se va a fundir. Lo simulan en varios programas de CAD. La mayoría de las veces, desarrollan prototipos para probarlos y cambian el diseño si es necesario. Tras hacer unos cuantos prototipos rápidos, finalizan la pieza de fundición.

Next, they design the mold or die for the process. Similarly, they create 3D models and develop a few prototypes. During this process, they take into account several crucial parameters:

1. The injection type plays a crucial role in die-casting ZAMAK alloys. Because they have a low melting point, the injection system must be hot enough to keep the metal liquid.
2. The number of cavities is another critical parameter here. Engineers arrange these cavities for the best results.
3. The parting system typically designs how the two halves of the die will look. Final part quality and finishing and trimming depend on the parting line.
4. The ejector system generally releases the part from the mold. Its design should be accurate so it doesn’t damage the final part.
5. Engineers also carefully arrange the cooling system for the whole process. An appropriate cooling system prevents many casting defects.
6. Choosing a suitable material for the mold is also crucial in this situation. High-quality tool steels are usually used for this job. Popular tool steels are H13, SKD61, 8407, and 8418.

Step #2: Preparing ZAMAK alloy

Una vez que el molde está listo, los ingenieros lo instalan con la máquina. A continuación, preparan la aleación ZAMAK. Se utilizan varias técnicas para refinar la aleación ZAMAK. Algunos métodos populares son el refinado térmico, la reacción química, el refinado electrolítico y el refinado por zonas.

Este método funde la aleación ZAMAK en un horno para darle forma líquida. En este caso se controla una temperatura adecuada, lo que garantiza que la aleación se funde uniformemente. Los ingenieros suelen eliminar las impurezas durante este paso.

After refining, the process keeps the molten metal in the injection chamber. Once again, the temperature is controlled correctly here. Furthermore, it is essential to ensure proper sealing. This controlled environment is crucial for preventing contaminations.

Step #3: Injecting the Molten ZAMAK into the Die

Injecting the molten ZAMAK alloy into the die is critical in the die-casting process. In the previous step, engineers usually prepare and keep the molten metal in the injection chamber. Indeed, this chamber is well-sealed and controlled.

El dispositivo de inyección utiliza un émbolo o pistón para introducir el metal fundido en la matriz. En este caso, es necesaria una determinada presión. Tenga en cuenta que, en función de esta presión, el tipo de fundición a presión puede variar. Sin embargo, la presión obliga al metal fundido a llegar a todos los rincones del molde, llenando la cavidad.

FYI: Proper injection technique is crucial for high-quality castings. Additionally, it guarantees a smooth and even surface finish. Therefore, when designing a mold, the injection channel must be well-planned.

Step #4: Cooling and solidifying the die-cast ZAMAK parts

Once the molten ZAMAK alloys fill the die, cooling begins immediately. Since the mold is made of high-quality tool steel, it quickly draws heat away from the molten metal. However, the mold has a rapid cooling system that helps cool and solidify the molten ZAMAK parts.

Different types of cooling systems can be used in various situations. In this case, water and air cooling are the most popular options. These systems offer consistent cooling rates. It’s important to note that high-quality ZAMAK parts require consistent cooling rates.

Para su información: Un sistema de refrigeración adecuado es siempre necesario para una solidificación consistente. También ayuda a evitar muchos defectos de fundición.

Step #5: Ejecting the Solidified ZAMAK Die-Casting Part

Once the ZAMAK alloy has solidified, it must be removed from the die. This step is typically called ejection.

FYI: An appropriate ejection ensures the part’s quality and integrity.

An ejector pin typically does this work. These pins help push the zinc casting part out of the die casting mold.

1. The die opens.
2. It separates into two halves.
3. The ejector pin activates.
4. They push against the casting. The casting is ejected out of the die.

El operario lo hace con mucho cuidado. Es evidente que demasiada fuerza puede dañar la pieza. Por lo tanto, alinear correctamente el pasador eyector evita marcas o abolladuras en la pieza final.

Paso #6 Acabado y recorte

After ejection, the part typically leaves behind an excess part that requires trimming. These excess parts are also called flashes. These flashes generally hamper the performance of the die-cast ZAMAK parts.

Foundries use different trimming machines depending on the situation. Grinding or polishing machines help a lot here. Some small-scale foundries may do it manually. However, various surface treatments are implemented on ZAMAK die-casting parts for further finishing.

Step #7: surface treatment

Como se ha mencionado en el paso anterior, se puede dar a una superficie un aspecto de primera calidad utilizando varios métodos. Se utilizan distintos métodos de tratamiento de superficies para distintas necesidades de aplicación.

El tratamiento de superficies es el último paso del método de fundición a presión ZAMAK. Principalmente mejora la estética de las piezas metálicas.

El cincado es uno de los métodos más habituales. Este proceso suele consistir en recubrir las piezas de ZAMAK con otro metal. Galvanoplastia de níquel negroEl cromo y el zinc son los materiales de revestimiento más utilizados.

Another widely-used method is painting. Painting generally adds color and extra protection. Although painting is not as effective as other methods, it is cheap and easy. You can do it either by spray paint or powder coating. Note that powder coating is generally more durable and resistant to chipping.

Anodizing is another effective technique, though it is less famous than plating. It increases surface hardness and corrosion resistance, for example, some zamak 3 or zamak 5 die castings that use acabado anodizado dorado for some furniture components.

There are other methods available for surface analysis. However, each method described above has its unique advantages and limitations. The choice mainly depends on your project needs and budget.

Aplicaciones de las piezas de fundición a presión ZAMAK

Como ya sabe, las piezas de fundición a presión ZAMAK ofrecen muchas ventajas. Estas ventajas hacen que las aleaciones ZAMAK sean perfectas para muchos usos. En esta parte se mostrarán algunas formas comunes en que se utilizan las piezas de fundición a presión ZAMAK. La siguiente tabla muestra algunas de las piezas de fundición a presión de ZAMAK más utilizadas en diversos sectores.

Recambios de automóvil

La industria automovilística utiliza con frecuencia piezas de fundición a presión ZAMAK. Estas piezas metálicas son fuertes y precisas, lo que las hace ideales para fabricar complicadas piezas de automóvil. También resisten condiciones duras y son ligeras. Estas ventajas son necesarias para el ahorro de combustible de su coche.

Equipos electrónicos

Las piezas ZAMAK son perfectas para esta industria. Estas aleaciones pueden utilizarse para fabricar una amplia gama de productos. Como sabe, los artículos eléctricos crean interferencias electromagnéticas. Las piezas de fundición a presión ZAMAK proporcionan un excelente escudo contra ellas.

Ferretería y mobiliario

Another benefit of the ZAMAK die-casting parts is excellent adhesion. Because of this, you can typically give these parts a premium look. Therefore, ZAMAK die-casting parts are widely used in many aesthetic applications. This feature is critical in hardware and furniture.

Fontanería y electrodomésticos

Las piezas de fundición a presión ZAMAK también resisten la corrosión. Estos metales ofrecen una excelente resistencia y maleabilidad, lo que los hace duraderos. Por ello, las piezas ZAMAK son frecuentes en fontanería y diversos electrodomésticos.

Toys and sporting goods

Finally, ZAMAK die-casting parts are widely used in the manufacturing of toys and sports items. It is ideal for making die-cast toy cars, model trains, and toy gun parts.

Fundición inyectada de zamak frente a aluminio: ¿Cuál es mejor?

Examinemos las capacidades de las mejores opciones. Resumimos sus características en la siguiente tabla, que puede ayudarle a elegir el material adecuado para su proyecto.

From the above table, you can see that ZAMAK die-casting parts offer some benefits. With the exception of ZAMAK 2, these die-casting parts boast a low melting point, excellent fluidity, and a high-quality surface finish. Therefore, they are ideal for use in the production of hardware and toys. Additionally, they offer low thermal and electrical conductivity. Therefore, ZAMAK die-casting parts are widely used in the production of many electronic gadgets.

On the other hand, aluminum die-casting parts give a high strength-to-weight ratio. Also, they offer high tensile strength, meaning you can use it to make many auto engine parts. Aluminum die-casting parts also provide high corrosion resistance. This makes them suitable for use in harsh weather conditions. Moreover, aluminum offers high thermal and electric conductivity. Therefore, aluminum is also used in electrical appliances. Go to the fundición a presión de zinc frente a aluminio page to learn more.

ZAMAK Die Casting Fabricante: GC Precision Services

GC Precision Mold Co. Ltd is a top ZAMAK die-casting manufacturer globally. They also work with materials like aluminum, magnesium, and bronze. Besides die casting, they offer sand and investment casting services.

GC Precision también ofrece diversos servicios de mecanizado CNC. Este preciso proceso de mecanizado es responsable de la alta calidad de las piezas de fundición a presión ZAMAK 3 y ZAMAK 5. Su avanzada tecnología garantiza excelentes resultados para todas las necesidades de fundición y mecanizado.

Si necesita cualquier servicio de fundición a presión de ZAMAK, no dude en Contacto. Our team of experts is always delighted to hear from you.

Preguntas frecuentes

¿Cuál es la durabilidad de ZAMAK?

ZAMAK’s durability is attributed to numerous factors:

1. It offers excellent corrosion resistance.
2. It has a decent hardness and tensile strength.
3. It offers a high strength-to-weight ratio.
4. It offers excellent adhesion.

Therefore, it allows for a variety of surface treatments. Overall, ZAMAK is a reliable and long-lasting material for industrial uses.

¿A qué temperatura se funde ZAMAK?

The melting varies from grade to grade. For example, ZAMAK 2 melts at 1446 degrees centigrade, while ZAMAK 3-12 melts at 380 to 440 degrees Celsius. Except for ZAMAK 2, other grades have low melting points. It makes the alloy ideal for die casting. A low melting point also gives faster cycle times and lower energy costs.

¿Cuál es el mejor ZAMAK para el casting?

The best ZAMAKs for die casting are ZAMAK 3 and 5.  They both are commonly used due to their excellent strength and flexibility. Die-cast ZAMAK 3 typically offers high fluidity and less shrinkage. On the other hand, the ZAMAK 5 die-casting alloy provides higher strength. It usually offers better hardness and tensile strength.

What is the lower limit for zinc die casting wall thickness?

El límite inferior del grosor de las paredes de fundición inyectada de zinc es de 0,5 mm o 0,02 pulgadas. Como usted sabe, ZAMAK ofrece una excelente fluidez y resistencia. Estas dos características generalmente mantienen paredes delgadas sin comprometer la resistencia.