Alloys of zinc and magnesium sport a wide range of physical and mechanical properties. The result is enormous flexibility in selecting die-casting materials for small, complex components. Designers have a broad latitude of materials to choose from for small die-cast components. Each of five zinc alloys, plus a magnesium option has strengths and weaknesses for particular applications. But as die-casting mediums, they have an advantage over materials such as aluminum. Their dimensional stability and predictable shrinkage rates ensure part-to-part consistency while low thermal mass permits high cycle rates. And designers often see a tenfold increase in die life thanks to the low abrasive wear rates of these alloys when compared to their aluminum counterparts. Special die-casting techniques let designers easily modify designs to boost structural properties. To improve creep resistance in a component with external or internal threads, for example, designers can increase thread count. Special hot-camber die-casting processes produce 360* external threads cast up to 50 threads/in. (20 threads/cm). Die casting lets the parts meet a thread tolerance class of 2A (6g) with no secondary deburring or chasing. Similarly, uniform wall thicknesses in a design distribute stresses more evenly. And precision tooling used in hot-chamber die casting helps eliminate secondary finishing or machining -- net-shape parts exit the mold "flash-free." Net-shape manufacturing is one of the main advantages of this die-casting method as it reduces material waste and part cost. The most common zinc alloys for hot-chamber die casting are Zamak 2, Zamak 3, Zamak 5, ZA-8, and ACuZinc. Overall, their mechanical properties compare favorably with brass and screw-machined steel. Zamak 3 is the most widely used zinc alloy. It offers the best combination of mechanical properties and economics. Zamak 2 and 5, with higher copper content, better resist wear. In addition, Zamak 5 offers higher creep resistance, while Zamak
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Zinc and zinc alloys are non-ferrous alloys that are used widely in the production of die cast components.
Metal casting involves the shaping of free-flowing liquid metals through the use of dies, molds or patterns.
Foundry equipment and foundry supplies used in die casting, investment casting and other metal casting operations.
Magnesium and magnesium alloys are nonferrous metals with low density, good ductility, moderate strength, and good corrosion resistance.
Nickel and nickel alloys are non-ferrous metals with high strength and toughness, excellent corrosion resistance, and superior elevated temperature properties.
Topics of Interest
Zinc, a crystalline metal with moderate strength and ductility, is seldom used alone except as a coating. In addition to its metal and alloy forms, zinc also extends the life of other materials such...
Automotive designers are specifying die-cast magnesium parts in applications once dominated by aluminum, zinc, and other structural materials. Production and New Program Manager, Magnesium and...
Special design techniques come into play when zinc die castings get a surface finish Tool Engineer and Program Manager Chromates meet a wide range of corrosion-resistant requirements: from olive drab...
As the lightest structural metal available, magnesium's combination of low density and good mechanical strength results in a high strength-to-weight ratio. Because of their low modulus of elasticity,...
OVERVIEW
Aluminium is one of the most versatile of the common foundry metals and the ratio of cast to wrought aluminium alloy products is increasing primarily because of the larger amounts of...
