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.

ZAMAKダイカスト 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.

バイヤー、エージェント、ディーラー、輸入業者は、この記事から貴重な情報を得ることができる。もし、あなたが以下のことを理解するための完全なガイドをお探しなら ZAMAKダイカストこれは、あなたが探すべきものです。さあ、始めよう。

ダイカストZAMAK合金のご紹介

ZAMAKとは、亜鉛、アルミニウム、マグネシウム、銅（Kupfer）の頭文字をとったもの。ドイツの金属合金名である。亜鉛が母材で、94%から96%まである。

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.

ZAMAK合金はダイカスト鋳造で広く使用されています。ZAMAK合金のダイカスト部品は多くの用途に普及しています。これらの鋳造部品は、自動車部品から電子機器やハードウェアに至るまで、非常に重要です。また、100%リサイクル可能です。

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.

ZAMAK合金のダイカストの種類

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.

ザマックダイカスト

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.

その他のZAMAK合金もご覧いただけます。次の表はZAMAK合金の種類をまとめたものです。この表は、その組成、利点、用途を強調しています。

テーブル 1 ダイカストZAMAK合金組成表

テーブル 2 ZAMAKダイカスト合金サマライズテーブル

なぜダイカストZAMAK合金を使うのか？

ZAMAK合金を使うべき理由はたくさんあります。その利点から、ZAMAK合金はアルミ鋳造に取って代わることもあります。このセクションでは、主にZAMAK合金のダイカストの利点についてお話します。

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

ダイカストZAMAK合金は強靭で変形に強い。このため、これらの合金は耐久性に優れ、連続運転でも良好な性能を発揮します。ZAMAK 2と5は高い剛性と靭性を提供します。

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.

この機能はダイカストでは非常に重要です。ギアやレバーのような可動部品にとって非常に重要な交換コストを削減します。

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.

この特徴により、一般的に原材料費が削減され、環境への影響もなくなります。なお、リサイクルされたZAMAK合金は、新しい材料と同じ品質を保持しています。

Reason #8: Cost-Effective

ZAMAKダイカスト合金は費用対効果の高いソリューションです。通常、アルミニウムよりも安価である。2024年の市場動向によると、ZAMAK金属はアルミニウムより若干高価である。しかし、ZAMAK合金は他の金属やその合金よりも安い。

ZAMAK合金のダイカスト鋳造の限界とは？

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.

ZAMAKダイカストとは？

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.

ZAMAK合金はHPDC、LPDC、重力ダイカストに適しています。ZAMAK合金の利点と限界については、すでによくご存知でしょう。

The ZAMAK die casting process

ZAMAKダイカスト 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.

まず、鋳造所のエンジニアが鋳造する最終部品の3Dモデルを作成する。それをさまざまなCADソフトでシミュレーションする。ほとんどの場合、テスト用のプロトタイプを作成し、必要に応じて設計を変更します。何度かラピッドプロトタイプを作成した後、鋳造部品を最終決定します。

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

金型の準備が整うと、エンジニアはそれを機械に取り付ける。次に、ZAMAK合金を準備する。ZAMAK合金の精錬には様々な技術が用いられる。一般的な方法としては、熱精錬、化学反応、電解精錬、ゾーン精錬などがある。

この方法では、ZAMAK合金を炉で溶かして液状にする。この場合、適切な温度が制御され、合金が均一に溶けるようにします。エンジニアは通常、この工程で不純物を取り除きます。

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.

射出装置は、プランジャーやピストンを使って溶融金属を金型に押し込む。この場合、一定の圧力が必要になります。この定格圧力に基づいて、ダイカストのタイプが異なる場合があることに注意してください。しかし、この圧力によって溶融金属は金型の隅々まで到達し、キャビティに充填されます。

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.

参考：安定した凝固には、適切な冷却システムが常に必要です。また、多くの鋳造欠陥を防ぐのにも役立ちます。

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.

オペレーターは非常に慎重に作業する。力を入れすぎると、部品が損傷することは明らかです。そのため、エジェクターピンを適切に位置合わせすることで、最終的な部品に跡やへこみがつくのを防ぐことができます。

ステップ#6 仕上げとトリミング

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

前のステップで述べたように、さまざまな方法で表面に高級感を与えることができる。さまざまな表面処理方法は、さまざまな用途のニーズに応じて使用される。

表面処理はZAMAKダイカスト法の最終工程です。主に金属部品の美観を向上させます。

亜鉛メッキはここで最も一般的な方法の一つである。このプロセスでは通常、ZAMAKの部品を別の金属でコーティングします。 黒ニッケル電気メッキクロム、亜鉛は一般的なメッキ材料である。

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 ゴールドアルマイト仕上げ 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.

ZAMAKダイカスト部品の用途

すでにご存知のように、ZAMAKダイカスト部品には多くの利点があります。これらの長所により、ZAMAK合金は多くの用途に最適です。このパートでは、ZAMAKダイカスト部品の一般的な使用方法を紹介します。以下の表は、さまざまな産業で使用されている一般的なZAMAKダイカスト部品を示しています。

カー用品

自動車産業では、ZAMAKのダイカスト部品が頻繁に使用されています。これらの金属部品は強度と精度が高く、複雑な自動車部品の製造に最適です。また、過酷な条件にも耐え、軽量です。これらの長所は、車の燃費に必要です。

電子機器

ZAMAKの部品はこの業界に最適です。これらの合金は様々な製品に使用できます。ご存知のように、電気製品は電磁干渉を引き起こします。ZAMAKダイカスト部品は、それに対して優れたシールドを提供します。

金物・家具

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.

配管＆アプライアンス

ZAMAKのダイカスト部品は耐腐食性にも優れています。これらの金属は優れた強度と可鍛性を持ち、耐久性に優れています。そのため、ZAMAKの部品は配管や様々な電化製品に使用されています。

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.

ザマックダイカストとアルミニウムの比較：どちらが優れているか？

より良い選択肢の能力を検証してみよう。以下の表にその特徴をまとめましたので、プロジェクトに適した素材を選ぶ際の参考にしてください。

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 亜鉛対アルミダイカスト page to learn more.

ZAMAKダイカストメーカー：GCプレシジョンサービス

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は、様々なCNC機械加工サービスも提供しています。ZAMAK 3およびZAMAK 5ダイカスト部品の高品質は、この精密な機械加工プロセスによるものです。GCプレシジョンの高度な技術は、あらゆる鋳造および機械加工のニーズに対して優れた結果を保証します。

ZAMAKのダイキャストサービスが必要な場合は、お気軽にお問い合わせください。 お問い合わせ. Our team of experts is always delighted to hear from you.

よくある質問

ZAMAKの耐久性は？

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.

ZAMAKは何度で溶けますか？

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.

キャスティングに最適なZAMAKとは？

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?

亜鉛ダイカストの肉厚の下限は0.5mmまたは0.02インチです。ご存知のように ZAMAK は優れた流動性と強度を提供する。この2つの特徴は一般的に、強度を損なうことなく薄い壁を保持する。