Secondary alloy choice is one of the key factors that influence the performance of ZAMAK molding. This is because it determines whether the part will be able to withstand the high pressures required to produce a good quality cast. In addition, it affects the cost of production and the weight of the component produced.
In addition, the choice of secondary alloy will also depend on the application of the finished part. For example, if the part is subjected to high temperatures during use, the alloy chosen must be capable of resisting high temperature oxidation. If the part is designed to resist wear and tear, then the alloy selected must possess excellent abrasion resistance.
Furthermore, the choice of secondary alloy influences the casting process itself. For instance, if the alloy chosen does not have the right properties to form a strong bond with the primary metal, the resulting cast will have weak joints. As such, the choice of secondary material cannot be overlooked. It is a crucial step in ensuring that the finished product meets the required specifications.
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What is ZAMAK?
ZAMAK is a Zinc-based alloy commonly used in die casting because it has good mechanical properties and a relatively low melting point. The term “ZAMAK” is actually an acronym for the four main elements in the alloy: Zinc, Aluminium, Magnesium, and Copper. The amount of Zinc found in ZAMAK typically ranges from about 95 to 99 per cent.
Although ZAMAK can be cast using various methods, die casting is the most common. In this process, molten ZAMAK is injected into a metal mold under high pressure. The resulting parts are typically very smooth and have a high degree of dimensional accuracy.
Properties of ZAMAK
As an alloy, ZAMAK possesses noteworthy material properties, the most prominent being higher rigidity as compared to standard Aluminium. Other useful properties of ZAMAK include resistance to corrosion, higher vibration damping rate, heat dissipation, a relatively low melting point and high fluidity when molten, as well as electromagnetic interference shielding. With these properties, die casting service providers are able to manufacture components such as heat sinks, hard disk casings, housings for steering wheel locks, and more.
Types of ZAMAK
As an alloy, ZAMAK is highly versatile, making it suitable for a wide range of applications. However, it is important to choose the right ZAMAK alloy for your specific application, as each one has its own unique set of mechanical and physical properties.
For example, ZAMAK 3 is the standard Zinc alloy used in die casting. It has good ductility and corrosion resistance, making it ideal for parts that need to be formed or shaped after casting. ZAMAK 5 on the other hand is tougher than ZAMAK 3 as it has additional Copper percentage to improve resistance, strength, and hardness. ZAMAK 5 is often used for components that require a higher degree of precision. As for ZAMAK 7, it is a high purity alloy that contains low levels of Magnesium, thus giving it better ductility to manufacture components that are more intricate in nature. ZAMAK 7 in terms of strength is likened to ZAMAK 5 but with better ductility.
Choose EKO for Your Die Casting Needs
If you are looking for a durable and versatile Zinc-based alloy for your next project, ZAMAK would be the best option. No matter which type of ZAMAK you choose, here at EKO Industries, you can be sure that your parts will have high degrees of accuracy and detail, as we work together with you to manufacture them to near net shapes. Contact us to find out more about our die casting processes or some of our other manufacturing capabilities today, and work with materials experts who have been in the business for over 20 years.