Another major category of die casting metals is zinc alloys. Castable in a hot-chamber die casting machine, zinc is the most manufacturer-friendly of die casting materials and offers other benefits like impact strength, ductility, and suitability for plating. Due to its castability, it also results in minimal die wear.
Zinc is heavier than aluminum and magnesium and is usually alloyed with aluminum, copper, and magnesium.
Common zinc die casting alloys include:
Zamak 3: A general-purpose zinc alloy that is easy to cast and offers excellent dimensional stability. In North America, more than two thirds of zinc die castings use Zamak 3. Example uses include ceiling fans and plumbing components.
Zamak 2: A slightly stronger and more expensive alloy with added copper content. It is often used to produce tooling for plastic injection molding.
Zamak 5: A zinc alloy close in composition to Zamak 3 but with greater tensile strength and lower ductility. Popular for products like automotive parts and wheel balancing weights.
Other die casting alloysOther die casting materials include copper, silicon tombac, lead, and tin alloys, in addition to zinc-aluminumalloy.
Copper alloys exhibit high strength, hardness, and corrosion resistance, in addition to excellent dimensional stability. Meanwhile lead and tin alloys are very dense and can be resistant to corrosion. Zinc-aluminum alloys are recognizable by the ZA prefix; those with a lower aluminum content can be hot-chamber die cast, but those with 11% or more typically cannot.
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