Zinc Die Casting
High pressure die casting zinc-based alloys is what A.M.E specialise in
Die casting is one of the most efficient manufacturing processes that can produce strong geometrically complex metal components with steel die casting tools that are also known as moulds.
There are several processes by which metals are processed into different forms. Die casting is one of the popular manufacturing processes. It is preferred above all other kinds of processes due to the quality of the finished goods and the ease of manufacture.
Zinc is a widely used and easily available metal which has several different variations to choose from to suit the individual specification.
Below are the specifications of the alloys we use:
Zinc Alloy Equivalents
This classifies international equivalents for Zinc die casting alloys.
|ZL2 (BS EN1774)||ZP2 (EN12844)||ZAMAK2 (ASTM B86)||-|
|ZL3 (BS EN1774)||ZP3 (EN12844)||ZAMAK3 (ASTM B86)||ZDC2 (JIS5301)|
|ZL5 (BS EN1774)||ZP5 (EN12844)||ZAMAC5 (ASTM B86)||ZDC1 (JIS5301)|
|ZL8 (BS EN1774)||ZP8 (EN12844)||ZA8 (ASTM B86)||-|
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The process is carried out on our fully automated die casting cells which are suitable to withstand high pressure. The molten metal is pushed by a hydraulically actuated plunger into a two-piece die casting tool (also known as a tool or mould) containing one or multiple impression cavities, each an exact inverse replica of the part or parts being produced.
Because of the fast chill and rapid solidification that takes place when the molten metal comes into contact with the die casting tool the cooling time can be anything from seconds to a minute dependant on the size and weight of the component.
When the component is cooled the machine will only then open the tool and the fully automated arm will reach in and take the component out of the die, lubricate the die casting tool and weigh the component to ensure it is correct. Once the cycle is complete the machine will automatically repeat this process until the desired quantity is reached.
Zinc alloy is melted and injected into a zinc pressure diecasting tool. The material solidifies and produces the shape and form in the diecasting tool within seconds.
The tool opens and ejects the diecasting shot. This process can be repeated 100s of times per hour reliably and repeatably.
A die casting tool can produce up to 1,000,000 shots from the life of one tool with good maintenance and replacing any wear parts on the tool throughout its life.
A die casting tool can have multiple impressions and each extra impression is a fraction of the cost of a secondary casting tool and so on.