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 trykkstøping 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.

Innkjøpere, agenter, forhandlere eller importører kan få verdifull informasjon fra denne artikkelen. Hvis du er ute etter en komplett guide for å forstå ZAMAK trykkstøpinger det denne du bør se etter. La oss komme i gang.

Vi presenterer ZAMAK Die Casting Alloy

ZAMAK står for sink, aluminium, magnesium og kobber (Kupfer). Det er et tysk navn på en metallegering. Sink er grunnmaterialet, som varierer fra 94% til 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.

ZAMAK-legeringer er mye brukt i trykkstøperier. Støpte deler i ZAMAK-legeringer er utbredt i mange bruksområder. Disse støpedelene er avgjørende for alt fra bildeler til elektronikk og maskinvare. De er også 100% resirkulerbare.

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.

Ulike typer pressstøping 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.

zamak pressstøping

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.

Du kan også finne andre ZAMAK-legeringer. Tabellen nedenfor gir en oversikt over ulike ZAMAK-legeringer. Tabellen fremhever deres sammensetning, fordeler og bruksområder.

Tabell 1 Tabell over legeringssammensetningen til ZAMAK Die Casting

Tabell 2 ZAMAK Die Casting Alloy Summerize Table

Hvorfor bruke ZAMAKs pressstøpelegeringer?

Det er mange grunner til at du bør bruke ZAMAK-legeringer. På grunn av fordelene erstatter ZAMAK-legeringer noen ganger støping av aluminium. Denne delen handler hovedsakelig om fordelene ved å støpe ZAMAK-legeringer.

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

ZAMAKs pressstøpte legeringer er seige og motstår deformasjon. Derfor er disse legeringene slitesterke og fungerer godt i kontinuerlig drift. ZAMAK 2 og 5 har høy stivhet og seighet.

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.

Denne egenskapen er avgjørende i pressstøping. Det reduserer utskiftingskostnadene, noe som er avgjørende for bevegelige deler som tannhjul og spaker.

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.

Denne egenskapen reduserer vanligvis råvarekostnadene og sikrer ingen miljøpåvirkning. Merk at resirkulerte ZAMAK-legeringer holder samme kvalitet som nytt materiale.

Reason #8: Cost-Effective

ZAMAKs pressstøpelegeringer er kostnadseffektive løsninger. De koster vanligvis mindre enn aluminium. Ifølge markedstrender i 2024 er ZAMAK-metaller litt dyrere enn aluminium. ZAMAK-legeringer er imidlertid billigere enn andre metaller og deres legeringer.

Hva er begrensningene ved pressstøping av ZAMAK-legering?

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.

Hva er ZAMAK Die Casting?

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-legering er egnet for HPDC, LPDC og tyngdekraftstøping. Vel, du er allerede kjent med fordelene og begrensningene.

The ZAMAK die casting process

ZAMAK pressstøping, eller 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.

Først lager ingeniørene fra støperiet en 3D-modell av den endelige delen som skal støpes. De simulerer den i ulike CAD-programmer. Som oftest utvikler de prototyper for testing og endrer designet om nødvendig. Etter å ha laget noen raske prototyper, ferdigstiller de den endelige støpestykket.

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

Når formen er klar, installerer ingeniørene den i maskinen. Deretter forbereder de ZAMAK-legeringen. ZAMAK-legeringen foredles ved hjelp av ulike teknikker. Noen populære metoder er termisk raffinering, kjemisk reaksjon, elektrolytisk raffinering og soneraffinering.

Metoden går ut på å smelte ZAMAK-legeringen i en ovn slik at den får flytende form. I dette tilfellet kontrolleres temperaturen slik at legeringen smelter jevnt. Ingeniørene fjerner vanligvis urenheter i løpet av dette trinnet.

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.

Injeksjonsenheten bruker et stempel eller stempel for å skyve det smeltede metallet inn i matrisen. I dette tilfellet er det nødvendig med et visst trykk. Merk at basert på denne trykkvurderingen kan typen støping variere. Trykket tvinger imidlertid det smeltede metallet til å nå hvert formhjørne og fylle hulrommet.

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.

Bare så du vet det: Et skikkelig kjølesystem er alltid nødvendig for jevn størkning. Det bidrar også til å forhindre mange støpefeil.

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.

Operatøren gjør det veldig forsiktig. Det er klart at for mye kraft kan skade delen. Ved å justere utkasterpinnen riktig unngår du derfor merker eller bulker på den ferdige delen.

Trinn #6 Etterbehandling og trimming

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

Som nevnt i forrige trinn kan du gi en overflate et førsteklasses utseende ved hjelp av ulike metoder. Ulike overflatebehandlingsmetoder brukes til ulike bruksområder.

Overflatebehandling er det siste trinnet i ZAMAKs pressstøpemetode. Det forbedrer hovedsakelig estetikken til metalldelene.

Forzinking er en av de vanligste metodene her. Denne prosessen innebærer vanligvis at ZAMAK-deler belegges med et annet metall. Galvanisering med svart nikkel, krom og sink er populære pletteringsmaterialer.

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 anodisering i gull 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.

Bruksområder for ZAMAK Die Casting Parts

Som du allerede vet, har ZAMAKs pressstøpte deler mange fordeler. Disse fordelene gjør ZAMAK-legeringene perfekte for mange bruksområder. I denne delen vil vi vise noen vanlige bruksområder for ZAMAK-drykkstøpte deler. Tabellen nedenfor viser noen vanlige ZAMAK-drykkstøpte deler som brukes i ulike bransjer.

Bildeler

Bilindustrien bruker ofte ZAMAKs pressstøpte deler. Disse metalldelene er sterke og nøyaktige, noe som gjør dem ideelle til å lage kompliserte bildeler. De tåler også tøffe forhold og er lette. Disse fordelene er nødvendige for bilens drivstoffeffektivitet.

Elektronisk utstyr

ZAMAK-deler er perfekte for denne bransjen. Disse legeringene kan brukes til å lage et bredt spekter av produkter. Som du vet, skaper elektriske gjenstander elektromagnetisk interferens. ZAMAKs pressstøpte deler gir et utmerket skjold mot dette.

Maskinvare og møbler

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.

Rørleggerarbeid og hvitevarer

ZAMAKs pressstøpte deler motstår også korrosjon. Disse metallene har utmerket styrke og formbarhet, noe som gjør dem holdbare. Derfor er ZAMAK-deler utbredt i rørleggerarbeid og ulike apparater.

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.

Zamak Die Casting vs Aluminium: Hva er best?

La oss undersøke mulighetene til de bedre alternativene. Vi oppsummerer egenskapene deres i følgende tabell, som kan hjelpe deg med å velge passende materiale for prosjektet ditt.

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 trykkstøping av sink vs. aluminium page to learn more.

ZAMAK Die Casting Produsent: 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 tilbyr også ulike CNC-maskineringstjenester. Denne presise maskineringsprosessen er ansvarlig for den høye kvaliteten på ZAMAK 3- og ZAMAK 5-pressstøpte deler. Deres avanserte teknologi sikrer utmerkede resultater for alle støpe- og maskinbearbeidingsbehov.

Hvis du trenger noen av ZAMAKs pressstøpetjenester, ta gjerne kontakt med kontakt oss. Our team of experts is always delighted to hear from you.

Ofte stilte spørsmål

Hvor slitesterk er 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.

Ved hvilken temperatur smelter 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.

Hva er den beste ZAMAK for støping?

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?

Den nedre grensen for veggtykkelse ved støping av sink er 0,5 mm eller 0,02 tommer. Som du vet, ZAMAK gir utmerket flyt og styrke. Disse to egenskapene holder vanligvis tynne vegger uten at det går på bekostning av styrken.