Die casting is an excellent way to create complex metal parts. This method is mainly suitable for a few metals. Some popular metals are zinc, copper, aluminum, and magnesium. Among these, zinc is vital and is prevalent in many applications. ZAMAK die-casting alloy is the most pervasive zinc alloy.
ZAMAK die-casting has different types: HPDC, LPDC, and gravity. Since ZAMAK has a low melting point, the HPDC method is mainly preferred. This article highlights what die-casting ZAMAK alloys are and their benefits. Moreover, it also discusses how foundries make the ZAMAK die-casting parts.
Buyers, agents, dealers, or importers can get valuable information from this article. If you are looking for a complete guide to understand ZAMAK die-casting, this is the one you should look for. Let’s get started.
Introducing Die Casting ZAMAK Alloy
ZAMAK stands for Zinc, Aluminum, Magnesium, and Copper (Kupfer). It is a German metal alloy name. Zinc is the base material, ranging from 94% to 96%.
ZAMAK alloys offer benefits that make these alloys suitable for die-casting. In short, they provide low melting point, high fluidity, and strength-to-weight ratio. They also have other benefits that you will know in the later sections.
ZAMAK alloys are widely used in die-casting foundries. Die-cast ZAMAK alloy parts are prevalent in many applications. These casting parts are crucial, from car parts to electronics and hardware. They are also 100% recyclable.
Moreover, they usually come with a wide range of surface finishes. Since they offer good adhesion quality, you can do many surface treatments on ZAMAK parts. Because of this, ZAMAK alloy parts can offer a premium look. Besides, they are prevalent in decoration applications, too.
Different Types Die Casting 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 r
zamak die casting
equire good flexibility.
Die-cast ZAMAK 3 & ZAMAK 5 die casting 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 prevalent in many applications.
You can also find other ZAMAK alloys. The following table summarizes different ZAMAK alloys. The table highlights their composition, benefits, and use.
Table 1 Die Casting ZAMAK Alloy Composition Table
|
ZAMAK Alloy Grade |
Zinc |
Aluminum |
Magnesium |
Copper |
Other |
|
ZAMAK Grade 2 |
Balance |
4% |
0.035% |
1% |
– |
|
Die Cast ZAMAK 3 |
Balance |
3.5 to 4.3% |
0.02 to 0.05% |
0.25% |
Fe <0.1%, Pb <0.005%, Cd <0.004% and Sn <0.003% |
|
ZAMAK 5 Die Casting |
Balance |
3.5 to 4.3% |
0.03 to 0.06% |
0.75 to 1.25% |
Fe 0.75%, Pb 0.004%, Cd 0.003% and Sn 0.002% |
|
ZAMAK Grade 7 |
Balance |
3.5 to 4.3% |
0.005 to 0.02% |
0.25% |
Fe 0.075%, Pb 0.003%, Cd 0.002% and Sn 0.001% |
Table 2 ZAMAK Die Casting Alloy Summerize Table
|
ZAMAK Alloy Grade |
Features |
Applications |
|
ZAMAK Grade 2 |
Strongest and hardest ZAMAK alloy |
Heavy-duty tools and machine parts |
|
Die Cast ZAMAK 3 |
Average strength, flexibility, and castability |
Car parts, hardware, and electrical housings |
|
ZAMAK 5 Die Casting |
Stronger and harder than ZAMAK 3, good creep resistance |
Gears, levers, and small machine parts |
|
ZAMAK Grade 7 |
Highest flexibility and fluidity |
Electrical terminals and connectors |
Why Use Die Casting ZAMAK Alloys?
There are many reasons why you should use ZAMAK alloys. Because of their benefits, ZAMAK alloys sometimes replace aluminum casting. This section mainly talks about the benefits of die-casting ZAMAK alloys.
Reason #1 High-Fluidity
Fluidity refers to how easily molten metal flows into molds during casting. High fluidity means that the ZAMAC alloy can easily do this job. Because of this feature, you can create even more complex designs. The molten metal can reach every corner of the design for high fluidity. As a result, you can get better finished parts.
Reason #2 Tough & High Rigidity
Die-casting ZAMAK alloys are tough and can resist deformation. Because of this, these alloys are durable and perform well in continuous operation. ZAMAK 2 and 5 offer high rigidity and toughness.
Reason #3 High Strength-To-Weight Ratio
Die-casting ZAMAK alloys are strong yet lightweight. Aluminum offers a stronger strength-to-weight ratio than ZAMAK. Note that aluminum’s tensile strength is 310MPa, while ZAMAK’s is 280MPa. However, ZAMAK die-casting parts are also prevalent in many uses.
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 on 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. Because of this, your final part can get a good appearance. You can give it a premium look as per your design. Besides, it also gives your metal part good corrosion resistance.
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.
This feature is critical in die-casting. It reduces replacement costs, which is crucial for moving parts like gears and levers.
Reason #7 100% Recyclable & 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.
This feature typically reduces raw material costs and ensures no environmental impact. Note that recycled ZAMAK alloys retain the same quality as new material.
Reason #8 Cost-Effective
ZAMAK die-casting alloys are cost-effective solutions. They usually cost less than aluminum. According to 2024 market trends, ZAMAK metals are slightly more expensive than aluminum. However, ZAMAK alloys are cheaper than other metals and their alloys.
What Are The Limitations Of Die Casting ZAMAK Alloy?
ZAMAK die-casting metals have many good points but also some problems. (1) These alloys have a low melting point. When used at varying temperatures, their properties change dramatically. However, when the temperature is too high, they become fragile.
(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.
What Is ZAMAK Die Casting?
ZAMAK die casting is a popular metal casting method. This method forces molten metal 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 die.
Usually, it has two halves: stationary and movable. When these haves 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, thus the name ZAMAK die casting.
ZAMAK alloy is suitable for HPDC, LPDC, and gravity die-casting. Well, you are already familiar with its advantages and limitations.
ZAMAK Die Casting Process
ZAMAK die casting, or zinc die casting is also a process similar to that of other materials. Foundries must ensure precise and efficient production to ensure high-quality outcomes. Starting 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 the most crucial part since it mainly determines everything.
First, engineers from the foundry create the 3D model of the final part to be cast. They simulate it on various CAD software. Most of the time, they develop prototypes for testing and change the design if necessary. After making a few rapid prototypes, they finalize the casting part.
Next, they design the mold or die for the process. Similarly, they create 3D models and develop a few prototypes. During this, they consider many essential 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. The parting line is crucial for the quality of the final part and is also necessary for the finishing and trimming processes.
(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) Finally, choosing a suitable material for the mold is also important here. High-quality tool steels are usually used for this job. Popular tool steels are H13, SKD61, 8407, and 8418.
Step #2 Preparing ZAMAK alloy
Once the mold is ready, engineers install it with the machine. Next, they prepare the ZAMAK alloy. Various techniques are used to refine the ZAMAK alloy. Some popular methods are thermal refining, chemical reaction, electrolytic refining, and zone refining.
The method melts the ZAMAK alloy in a furnace to give it a liquid form. A proper temperature is controlled in this case, ensuring the alloy melts evenly. Engineers usually remove the impurities during this step.
After refining, the process keeps the molten metal in the injection chamber. Once again, the temperature is controlled correctly here. In addition, proper sealing is also necessary. 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. Engineers usually prepare and keep the molten metal in the injection chamber in the previous step. Indeed, this chamber is well-sealed and controlled.
The injection device uses a plunger or piston to push the molten metal into the die. In this case, a certain pressure is necessary. Note that, based on this pressure rating, the type of die-casting may vary. However, the pressure forces the molten metal to reach every mold corner, filling the cavity.
FYI: Proper injection technique is crucial for high-quality castings. In addition, it also ensures 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 Casting 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 helps cool and solidify the molten ZAMAK parts.
Different types of cooling systems can be used in various situations. Water and air cooling is the most popular in this case. These systems offer consistent cooling rates. You know, this even cooling is extremely necessary for high-quality ZAMAK parts.
FYI: A proper cooling system is always necessary for consistent solidification. It also helps in preventing many casting defects.
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 part out of the mold. (1) The die opens. (2) It separates into two halves. (3) the ejector pin activates. (4) They push against the casting. It gently forces it out of the die.
The operator does it very carefully. It is evident that too much force can damage the part. Therefore, properly aligning the ejector pin avoids marks or dents on the final part.
Step #6 Finishing & Trimming
After ejection, the part usually comes with an extra part that needs 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 based on different situations. 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
As mentioned in the previous step, you can give a surface a premium look using various methods. Different surface treatment methods are used for varying application needs.
Surface treatment is the final step of the ZAMAK die-casting method. It mainly improves the aesthetics of the metal parts.
Zinc plating is one of the most common methods here. This process typically involves coating ZAMAK parts with another metal. Black Nickel electroplating, chrome, and zinc are popular plating materials.
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 casting that use gold anodizing finish for some funiture components.
There are other surface methods as well. However, each method described above has its unique advantages and limitations. The choice mainly depends on your project needs and budget.
Applications of ZAMAK Die Casting Parts
As you are already familiar with, ZAMAK die-casting parts offer many benefits. These pros make ZAMAK alloys perfect for many uses. This part will show some common ways ZAMAK die-casting parts are used. The following table highlights some common ZAMAK die-casting parts used in various industries.
|
Industries |
Use Examples |
|
Car Parts |
Door handles, knobs, clusters, AC ventilators, sound systems, seat belt adjusting parts, engine components, starters, and car electronic gadgets. |
|
Electronics Gadgets |
Laptop castings and parts, tables, mobile phones, headphones, TV remotes |
|
Hardware |
Grips, levers, pulls, joints, drawer tracks, decorative furniture |
|
Plumbing |
Tap handles, showerheads, appliance dials, and switches, ornamental edging |
|
Toys & sports items |
Cast toy vehicles, mini trains, toy firearm parts, and sports gear parts. |
Car Parts
The auto industry frequently uses ZAMAK die-casting parts. These metal parts are strong and accurate, which makes them ideal for making complicated car parts. They can also survive harsh conditions and are lightweight. These pros are necessary for your car’s fuel efficiency.
Electronic Equipment
ZAMAK parts are perfect for this industry. These alloys can be used to make a wide range of products. As you know, electric items create electromagnetic interference. ZAMAK die-casting parts provide an excellent shield against it.
Hardware and furniture
Another benefit of the ZAMAK die-casting parts is good adhesion. Because of this, you can typically give these parts a premium look. Therefore, ZAMAK die-casting parts are prevalent for many aesthetic applications. This feature is critical in hardware and furniture.
Plumbing & Appliances
ZAMAK die-casting parts also resist corrosion. These metals offer excellent strength and malleability, making them durable. Therefore, ZAMAK parts are prevalent in plumbing and various appliances.
Toys & Sport Goods
Finally, ZAMAK die-casting parts are also prevalent in toy and sports item manufacturing. It is ideal for making die-cast toy cars, model trains, and toy gun parts.
Zamak Die Casting vs Aluminum: Which is Better?
Let’s examine the capabilities of the better options. We summarize their characteristics in the following table, which can help you choose the suitable material for your project.
|
Aspect |
ZAMAK die casting |
|
|
Material |
Zinc, aluminum, magnesium, and copper |
Mainly aluminum |
|
Melting Point |
380°C to 1446°C |
463°C to 671°C |
|
Fluidity |
Very high |
High |
|
Strength to Weight Ratio |
High |
Very high |
|
Corrosion resistance |
Moderate |
Very high |
|
Weight |
Relatievly heavier |
Lighter |
|
Thermal conductivity |
Lower |
Higher |
|
Electrical conductivity |
Moderate |
Higher |
|
Hardness |
95 to 115 Brinell |
75 to 120 Brinell |
|
Tensile Strength |
263 MPa to 317 MPa |
290MPa to 325MPa |
|
Yield Strength |
200MPa to 317 MPa |
130 to 170 MPa |
From the above table, you can see that ZAMAK die-casting parts offer some benefits. It has a low melting point (except ZAMAK 2), fluidity, and excellent surface finish. So they are suitable for making hardware and toys. Besides, they also offer low thermal and electrical conductivity. Therefore, ZAMAK die-casting parts are prevalent in making 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. Because of this, they are also suitable in hard weather conditions. Moreover, aluminum offers high thermal and electric conductivity. So, they are also used in electrical appliances as well. go to zinc vs aluminum die casting page to know more.
ZAMAK Die Casting Manufacturer: 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 also provides various CNC machining services. This precise machining process is responsible for the high quality of ZAMAK 3 and ZAMAK 5 die casting parts. Their advanced technology ensures excellent results for all casting and machining needs.
If you need any ZAMAK die-casting services, feel free to contact us. Our team of experts is always happy to hear from you.
Frequently Asked Questions
How Durable Is ZAMAK?
ZAMAK is highly durable due to many reasons. (1) It offers excellent corrosion resistance. (2) It has a good hardness and tensile strength. (3) It offers a high strength-to-weight ratio. (4) It offers good adhesion. Thus, you can do many surface treatments on it. Overall, ZAMAK is a reliable and long-lasting material for industrial uses.
What Temperature Does ZAMAK Melt At?
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.
What Is The Best ZAMAK For Casting?
The best ZAMAK for die casting is 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?
The lower zinc die-casting wall thickness limit is 0.5 mm or 0.02 inches. As you know, ZAMAK offers excellent fluidity and strength. These two features generally hold thin walls without compromising strength.