Properties of Zamak components for the textile industry

 In previous posts in this blog we described the properties of Zamak for the application in different industries, including: lighting, building, electronics, electromechanical, household appliances. As we have already observed, the chemical and physical properties of the raw material and the surface and finishing treatments to which the components can be subjected therefore make Zamak a versatile material, capable of satisfying various types of aesthetic, mechanical or safety requiremensts. For applications on textile machineries also.

The properties required to Zamak components for textile machineries are mainly mechanical: the components must be able to dampen the vibrations of the machinery on which they are installed, to resist the strong wear caused by the sliding of the wires on them and they must have, already during the casting phase as to reduce costs, a precision with very narrow tolerances of the shapes.

In this sector of application also, the fluidity of Zamak is therefore fundamental because it allows to obtain a high degree of detail and complex shapes directly during the casting phase. Moreover, it is also fundamental the excellent surface quality of the Zamak die casts.

Let’s now see in detail these three characteristics of Zamak that are so important for textile machineries components.

Anti-vibration property

 In the textile industry Zamak components are employed in rotor spinning with a single spinning head technology: a technology that can overcome the limits of belt drive and in which the use of antivibration materials is essential. Textile machineries of this kind can in fact have rotor rotation speeds up to 180K revolutions per minute, with an output speed of up to 300K thousand revolutions per minute. This is why it is fundamental to employ HIDAMET (High Damping Metals) raw materials, such as zinc alloys, to make components subjected to this kind of stress. Zinc alloys, in fact, have an excellent damping capacity and this is why they prove to be a perfect choice for this field of application.

To find out more on the anti-vibration properties of zinc alloys we suggest to read the essay of I. Ritchie, Z. Pan e F. Goodwin, Characterization of the damping properties of die-cast zinc-aluminum alloys that can be found here.

Wear resistance

 Wear resistance is a fundamental requirement for components installed inside textile machineries. The sliding of the yarn on the component in fact subjects it to strong stresses which, over time, could damage it by eroding it.

Wear resistance in Zamak components is achieved through different strategies. First of all, the die-casting technology with which the zinc alloys are treated allows to obtain a surface layer, called “foundry skin”, of about 0,2-0,3 mm. The dense fine-grained microstructure of the “foundry skin” gives the zinc components a wear-resistant surface, as reported in the table below.

The tests were conducted on cylindrical specimens of 15 mm in diameter pressed on a hard cast iron disk, dampen with water carrying fine sand with a variable load. After a number of turns corresponding to a path of 10K cm, the thickness of the removed layer is measured. The value, expressed in tenths of a millimeter, provided the relative abrasion data. Zamak alloy, in the conditions in which the tests were carried out, is less consumable than ordinary brass while it is lower only than the 90/10 bronze. (The reported data derive from: L. Andreoni, Quaderno della colata a pressione delle leghe di zinco, Le leghe di zinco, Zama, ed. Edimet, Brescia, 1998).

Another strategy to increase the resistance of Zamak components for textile machineries is to subject them to specific surface treatments. In this case the components are placed on a tray immersed in a chemical bath where, thanks to the rotation given to the tray, they are able to absorb the chemical agent which, depositing itself on the surface, turns into a protective coating.

Possibility to obtain complex shapes and surface quality

The fluidity of Zamak allows to fill even the smallest cavities of the mold obtaining, already during the casting phase, small details and complex shapes. This property proves to be fundamental in an industry, such as the textile industry, in which the tolerances are very narrow and the components, to fulfill their mechanical function, are assembled together.

To deepen your knowledge on these themes we suggest you to read Thin walls thickness: a competitive advantage in zinc die casting.

Surface quality is also an important requirement for components intended for textile machineries. In fact, surface defects such as irregularities, bubbles or burrs could damage the yarn breaking it. Even in an industry such as the textile industry, where the requirements for the components are mainly mechanical, the possibility of obtaining an excellent surface quality directly during the casting phase and of being able to carry out various types of treatments and processes is therefore important.

To find out more on the surface treatments that is possible to carry out on Zamak components we suggest to read Coating, plating and other kind of surface treatments and Processing techniques for metal finishing.

Review of Zamak components for textile machineries

After analyzing the charateristics that make Zamak an excellent raw material for the production of components for the textile sector, let’s now examine some products that allow us to shed further light on the applications of zinc alloy die casting useful in this sector.

Adapter

The adapter is part of the spinning unit of rotating frames. In detail, it is installed on the machines that produce the type of cotton thread called “open end”: a thread intended for thick fabrics such as those of jeans or some shirts and which is opposed to the finer thread that is obtained in two phases, a first phase in which short pieces are made and a second in which the pieces are spliced generating an endless thread.

The component is placed in series on machines with 300/500 units, each independent in the production of cotton thread starting from cotton that is washed and centrifugated in order to make it homogeneous.

All the properties illustrated above are fundamental for this component: the anti-vibration property allows to dampen vibrations and it prevents the thread from slipping, the wear resistance allows the surface not to deteriorate, the fluidity of Zamak allows to obtain, directly during the casting phase, the details that are visible in the image of the post while the surface quality proves to be fundamental for keeping the yarn intact.

Feed Tray Bracket

Feed tray brackets are component derived from the assembly of two articles: feed table and holder.

Both the feed table and the holder have holes inside which magnets are installed, the assembly is therefore possible by magnetic force. The feed tray bracket, differently from the adapter, does not come in direct contact with the yarn and for this reason no particular surface qualities or resistance to wear are required. Zamak, in this case, was chosen for two fundamental reasons: the anti-vibration property and the possibility of obtaining a high degree of detail directly during the production phase.

The anti-vibration property is essential because the component is inserted in a jack rotating at 180K revolutions per minute and, if not able to dampen vibrations, it would risk hitting the other components with which it is in contact causing damage and breakage. The possibility of obtaining a high degree of detail results important for the making of the features of the object, such as, for example, the housing of the magnets that allow the assembly of the article.

Conclusions

In this post we analyzed some Zamak components that can be made for textile machineries, solutions that allow to illustrate the properties of zinc alloys and that result as a winning choice for this kind of mechanical applications.

For more information and updates subscribe to our blog, if you wish to consult our technical office to find out more applications of zinc alloy die cast components for the textile sector fill out the form.

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Industrialization of the product in zinc die casting

Industrializing a product means facing the entire design process taking into account the functional, qualitative and aesthetic specifications of the customer and of the construction technology, which in this case is the hot camber die casting of zinc alloys.

The industrialization of the product is therefore a complex process composed of various phases in which various departments intervene. Let’s analyze the delicate process that leads to mass production.

DFM

Already in the RFQ (Request For Quotation) phase, therefore still in the commercial phase, the project proposed by the customer is evaluated and analyzed in order to present an offer. Afterwards, once the sales process has been completed and the order from the customer has been received, the most substantial and vertical activities are undertaken. One of these activities is, for example, co-design: a phase in which the technical departments of the customer and of the supplier work together to optimize the product.

The study undertaken on the product, the co-design activity mentioned above, makes it possible to propose a series of activities aimed at increasing value and reducing costs, both as regards the product and the production process. The work carried out at co-design level culminates with the drafting of Design for Manufacturing, called in technical jargon DFM, a document that defines the most suitable shapes for the production process of the die cast and the tools that are necessary in the different phases of the process: mold, automations, frame for superficial treatments and others.

For a definition of DFM approved by the scientific community and for additional related information we recommend visiting the Society of Manufacturing Engineers website.

It is important to underline how the modifications suggested in this phase not only concern the aesthetic aspect or the functionality of the product, but also the resolution of problems emerged during the study phase: whether they are at product level, such as critical areas and deformation or too narrow tolerances, or at process level, for example it could be necessary to find alternative solutions for the configuration of the mold extractors.

For further information on DFM we suggest you to read the article Product design for die casting: how to speed up and optimize your DFM.

Kick-off

Once this initial phase has ended, it is time to bring together for a second time all the actors involved in the process with a meeting called kick off. The kick-off is the moment of the launch, typically it is a meeting called by the Project Manager in which all the departments involved in the realization of the project come together to discuss the production aspects. During the meeting, conducted by the Project Manager, the following areas intervene:

• Design: designers highlight the critical aspects of the product and the solutions identified at design level
• Quality: on the basis of the observations of the designers it identifies the elements on which it will have to focus its attention and the kind of analysis that it will be necessary to undertake to guarantee the respect of the requirements of the customer
• Production: it evaluates the technical aspects of the productive process and the relative criticalities, establishing machines, automations and processes necessary for the realization of the product
• Logistic: it manages the warehouse and its critical issues and the shipping of the goods to the customer
• Sales and marketing department: oversee communication with the customer at every stage of the project life, providing feedback on the progress of the processes

Kick-off is a very important moment because at the end of the meeting all the departments are ready to act together for the success of the project. At the end of the kick-off is therefore possible to start the construction of the tools necessary for production.

Sampling

During sampling phase the first samples, defined first off tool, are created. It is in this phase that the die casting mold and all the tools that will be necessary during mass production phase are tested.

All production departments contribute to the evaluation of the samples that are subsequently sent to the customer in order to obtain the approval.

Samples allow the verification of the compliance of the product to the requirements of the customer and the necessary analysis are undertaken by quality department and afterwards by the customer.

Samples, beside die casting process, can undergo different kinds of treatments. In some cases raw parts are sent to the customer, in other cases mechanical operations or superficial treatments are necessary.

In the case of superficially processed samples, external suppliers are involved. In this case it becomes necessary to carry out checks on the products arriving from suppliers and consequently on those delivered to the customer. In fact, it is important to monitor quality throughout the entire supply chain so as to guarantee to the customer products that are always compliant and that have passed strict controls.

Pre-Series

If sampling is aimed at the analysis of the quality and the dimensions of the samples the pre-series allows the verification, on a reduced scale, of the compliance to the established standards for the productive process.

In pre-series phase in fact the products are created with all the techniques and the processes that will be undertaken in phase of mass production allowing the verification of cycle time, of the production capacity of the plant and the respect of the parameters set in design phase.

Since the runs of the pre-series are limited and sometimes the product or the mold have to be subjected to modifications, in zinc alloys die casting it is advisable to carry out the pre-series, and the previous sampling, with prototypal molds. The prototypal molds do not have the lifespan of the molds for mass production but they are more suitable for the execution of modifications.

Importance of collaboration

We have seen how in the industrialization of the product expertise from different departments intervene at different levels and in different phases of the process. The operative bonds between the different departments become particularly evident in this phase and they are decisive in the functions of coordination, timing, management of the resources and project management.

Moreover, in industrialization phase the collaboration goes beyond the boundaries of the company and it involves customers and suppliers. In fact, the process of co-design can be undertaken only together with the customer and it is thanks to collaboration with the latter that it is possible to establish strategies aimed at reducing costs and at optimizing the product.

Also the collaboration with suppliers becomes fundamental because only through a careful monitoring of the entire production chain  it becomes possible to guarantee the quality of the products and to obtain the approval of the customer.

Conclusions

In this brief article we have described the phases that precede mass production of a component, then focusing on collaboration that is necessary for the success of any project, in particular in a delicate phase as the industrialization of a product.

In conclusion, we believe it is important to underline how, in this process, the Project Manager is a key figure that has to constantly monitor the processes and the contribution of every department verifying that, step by step, all the necessary operations are performed. It is only through the right collaboration that, in an articulate process composed by a number of steps, it becomes possible to achieve the goal in the best and efficient way.

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Minimum wall thickness

The characteristic of zinc alloys that allows the achievement of a particularly thin wall thickness is the capability of filling small cavities. Thanks to this feature zinc alloys can reach an average minimum thickness of 0,4 mm: an extremely low value, especially if compared to the average aluminum rate, as shown in the table below:

Thin wall thickness obtained with die casting process is determined by different factors, such as the shape of the component and the extension of its surface. Another factor that influences the thickness of the wall is the distance between the thin walls and injection point: lower the distance, thinner the wall.

Thanks to its filling capability and the possibility of obtaining a high rate of precision, zinc alloys allow the production of components that do not need further mechanical operations. Indeed, right after die casting process they already have precise finishing and thin wall thickness.

The advantages of thin wall thickness

So, why is the capability of obtaining thin wall thickness an added value when producing a die cast?

Below a list of the main advantages that result from thin walls both in terms of features of the product and cost and energetic savings:

1. Weight reduction of the component
2. Size reduction of the component
3. Possibility to obtain components with a high degree of detail
4. Resistance
5. Energy saving
6. Cost saving

1. Weight reduction of the component

Achieving a weight reduction of the component while maintaining its functionality is one of the main advantages of thin wall thickness in zinc die casting. As a matter of fact in specific sectors, for example in the automotive industry, to have the chance of reducing the weight of a component and at the same time to preserve its functionality represents an important benefit in terms of efficiency. This is particularly true for some specific components, such as car handles and sunroofs.

Thanks to the design freedom offered by zinc alloys the die casting supplier can analyze, starting from the original drawing, the shape of the product and collaborate with the customer for the identification of the areas of the product that can undergo a thickness reduction without compromising the functionality of the component but, on the contrary, enhancing it.

The cooperation between customer and supplier, a service defined co-design, can therefore lead to the development of innovative solutions able to increase product performance while, at the same time, generate a cost reduction provided by an inferior amount of raw material that has been used.

The percentage of weight reduction of the component is clearly variable, because it depends on the characteristics of every single product. Starting from the original project until reaching the new project redefined together with the customer, in some cases it is possible to achieve a weight reduction up to 50%. It is a percentage of considerable importance that is unlike to be reached with other materials.

For further information about weight reduction in die casting, read this post: Weight reduction: lightweight as a benefit of co-design

2. Size reduction of the component

Weight reduction is not the only important factor for the functionality of a product, indeed also dimension is very relevant, especially for those devices whose technological development require increasingly reduced dimensions.

Through the process of co-design the die casting supplier, together with the customer, studies solutions aimed at achieving this optimization by identifying the areas of the shape of the product that can undergo a wall thickness reduction.

In particular, products with a housing function, such as electronic connectors, need thin wall thickness in order to be more functional. Indeed these products contain in their inside other components and, in order to avoid space and obstacles issues, it is necessary that their walls are as thin as possible. Moreover, for this kind of products, zinc alloys are a winning choice because beyond the capability of reaching thin wall thickness they also maintain unaltered the electromagnetic shielding properties, which are extremely important for electronic industry.

Still as regards products with a housing function, for example cases for windows and doors handles, which do not have a primary mechanical function, zinc alloy are ideal because it allows the achievement of thin walls also with complex and unusual shapes. Usually this type of products is produced with metal sheet, a highly elastic material that, if treated with the deep drawing process, can reach an extremely thin thickness. However deep drawn metal sheet, unlike zinc alloys, does not offer design freedom because it does not allow the achievement of the complex geometries that can be obtained through die casting process.

If you want to have a look at a housing product with thin walls that, thanks to co-design, has achieved a size reduction and thinner walls, with a great saving for the customer, you can watch this video

3. Possibility to obtain components with a high degree of detail

As already said, with zinc die casting it is possible to obtain extremely precise products with complex shapes. Those shapes are often characterized by a great number of very small details, especially with products such as connectors and heat sinks that present a complex rib design.

Thanks to the reduction of wall thickness obtained with the die casting process those tiny details can be realized with extreme precision, thus assuring dimensional accuracy and efficiency of the product. Furthermore, the achievement of thin wall thickness in this kind of products adds value because it confers elasticity and therefore facilitates assembling and blocking systems.

Tests performed on thin wall zinc alloys samples have indeed highlighted results that are comparable with those of plastic materials: in particular, the elastic modulus of zinc alloys samples proved to be superior to that of nylon 6.

4. Resistance

Thin wall thickness does not mean inferior resistance. On the opposite, thinner walls have a crystalline structure that is more subtle than the one of components with thicker walls. This structure has superior mechanical properties, so the product is characterized by a high degree of resistance.

During the die casting process, the rapid superficial cooling generates what is generally defined “skin”, a superficial layer of 0.2-0.3 mm with a thin structure. The results of fatigue tests performed on zinc alloys diecastings with thin walls showed the advantage resulting from the presence of the “skin”. Indeed, in a diecasting with thin wall thickness the crystalline microstructure is greater in percentage terms and this gives greater resistance to the component.

Furthermore, other tests on thin wall thickness diecastings, pointed out fatigue strength values remarkably superior to those of zinc alloys treated with other technologies.

6. Energy saving

The achievement of thin wall thickness and the production of components with this feature allow the reduction of the quantity of energy used during the production process. Thin wall thickness indeed entail a reduction of the amount of raw material to be used and this, in the first place, translates into an inferior quantity of raw material to be re-casted.

In addition, components with thin walls have reduced cooling times and this generates not only an energy saving related to the functioning of the die casting machines, but also an increased energy efficiency of the whole process and a consequent reduction of production times.

7. Cost saving

The use of a lesser amount of raw material, the increased energy efficiency, the speeding-up of the productive process and the reduction of weight and dimensions, with the resulting transport costs saving, are all factors that lead to a considerable reduction of production costs. The cost saving resulting from the production of components with thin walls thus translates into an important benefit not only for the supplier, but also for the customer.

Zinc die casting is therefore a competitive technology from an economic point of view, it indeed allows the achievement of thin wall thickness and it is the ideal choice for the production of light and resistant components, characterized by complex and detailed shapes.

For an overview on components produced in Bruschi, including products with thin wall thickness, click here

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Zinc alloys are an excellent material for the production of resistant, aesthetically appealing and complex shaped components: they can indeed be used to meet the requests of various and different industries, from automotive to building sector, ensuring high performance standards, both from a functional and an aesthetical point of view. Taken into account the different characteristics required by each sector it is therefore fundamental to conduct a thorough analysis of zinc alloys with the aim of identifying the most appropriate one for the purpose we would like to reach, examining the requirements of the product and looking for a zinc alloy with the right properties to meet these demands.

In order to conduct this analysis it is essential to know zinc alloys classification, which can be divided into two main categories: ZAMAK alloys, whose name is composed of the word Alloy followed by a number on the basis of their sequential development, and zinc alloys classified with the prefix ZA, which have a remarkable higher percentage of aluminum compared to the previous ones and are therefore provided with a greater resistance.

At the beginning ZAMAK was a trademark registered by New Jersey Zinc Co., the first company to use this specific alloy, but with the passing of time it has been chosen as the common name to define all zinc alloys for die casting. Only with the development of numerous types of alloys the nomenclature of zinc alloys has become more structured, as we have seen with the distinction between ZAMAK and ZA alloys: however, ZAMAK is still considered the most common and conventional name to indicate a zinc alloy.

This acronym indeed defines a zinc alloy composed of four main metals: zinc, aluminum, magnesium and copper (Kupfer in German). These elements occur in zinc alloys in different percentages: alloys indeed differ on the basis of the concentration of each metal, thus showing different characteristics that affect the features of the diecast. These characteristics are crucial for the choice of the most suitable zinc alloy for one’s own technology and production process. ZAMAK can indeed be worked with different production processes: hot chamber die casting, cold chamber die casting, spin casting, sludge casting and gravity die casting. In this article we are going to focus on the best zinc alloys for hot chamber die casting, the technology that Bruschi employs for its business.

The main zinc alloys used for hot chamber die casting are:

• Alloy 2
• Alloy 3
• Alloy 5
• ZA8

ZA8 is the only alloy, among the previous ones, that does not belong to ZAMAK classification because it contains a high quantity of aluminum that categorizes it as ZA: it is however an especially suitable alloy for hot chamber die casting and for this reason it has been included in this analysis.

As anticipated, these alloys have different compositions: they are indeed composed of the same elements but they are dosed in different percentages, so as to enhance specific characteristics such as resistance or fluidity. The following table shows the composition of the previously listed zinc alloys, defined by the European regulations EN 12844 European Standard for Zinc Alloy Castings and EN 1774 Zinc and zinc alloys – Alloys for foundry purposes – Ingot and liquid:

Zinc alloys chemical composition

The table highlights the different concentrations of the materials in the different zinc alloys, especially aluminum and copper concentrations: these two elements are indeed the ones that mainly influence the characteristics of the alloys.

Zinc alloys for hot chamber die casting

Alloy 2

Alloy 2 is characterized by high resistance and hardness: it is indeed the most resistant alloy among all zinc alloys. Aluminum percentage is equivalent to that of Alloy 3 and Alloy 5, while copper quantity is definitely higher: it can reach 3,3% and it is precisely this high copper percentage that provides an excellent resistance to the alloy. However, over time such a high amount can lead to the alteration of specific characteristics of the alloy: during metal aging it is indeed possible to observe some issues related to dimensions, such as a small dimensional variation. Furthermore, due to aging, the alloy can be subjected to performance decrease, which can reach levels similar to those of aluminum alloys: as a matter of fact, the main disadvantage when employing Alloy 2 is related to performance reduction, particularly a reduction of ductility over time. Despite this performance loss caused by aging, Alloy 2 is an excellent material for die casting thanks to its exceptional castability and creep performance, as well as its ability to maintain high resistance and hardness standards also during long-term aging.

Alloy 3

Alloy 3 is the most popular zinc alloy in North America: it is indeed the mostly used alloy because of its excellent castability and dimensional stability over time. Alloy 3 has a superior dimensional stability compared to the other alloys, however this high stability degree is only significant when very narrow tolerances are required. As far as resistance is concerned, Alloy 3 is characterized by a low percentage of copper that implies a lower resistance compared to the other zinc alloys but, at the same time, it reduces the likelihood of alterations due to material aging, thus avoiding dimensional shrinkage and maintaining a constant performance over time. This zinc alloy is also perfect for the production of components that need surface treatments, such as plating, painting and chroming.

Alloy 5

Alloy 5 is the most commonly used zinc alloy in Europe. This alloy has outstanding castability properties and, compared to Alloy 3, it contains a slightly higher copper percentage that gives the alloy a superior resistance and hardness, as well as a better creep performance. This higher copper quantity is though responsible, as previously seen, for an inferior ductility that can affect the processability of the alloy during secondary operations such as bending, riveting, pressing or crimping. Similarly to Alloy 3, Alloy 5 is an excellent choice for products that require surface finish treatments.

ZA 8

ZA8, as suggested by the classification ZA and not Alloy, is characterized by a chemical composition that has a high aluminum amount, considerably higher compared to the other zinc alloys. This high aluminum concentration provides the alloy with a superior resistance, hardness and creep performance in relation to the other alloys, except for Alloy 2 that has very similar features. ZA 8, like the other alloys, is appropriate for surface finish processes such as chroming and painting.

Main characteristics of zinc alloys

Through the analysis of the chemical composition of zinc alloys it is therefore possible to define which alloy is the most appropriate for one’s own sector, not only on the basis of mechanical and physical properties of zinc alloys, but also with regard to the features of the product that has to be realized.

The choice of the best zinc alloy for hot chamber die casting indeed starts from an examination of the characteristics of the component:

• Which are its most significant features?
• Is it an aesthetical or a functional product?
• Will it undergo surface treatments?
• Does it require a higher resistance or a greater dimensional stability?

Answer similar questions and therefore conduct a careful analysis of the requirements of the product is indeed the first step for the choice of the raw material.

Once the main characteristics of the product have been identified, it is possible to analyze the properties of the different zinc alloys.

As their previous descriptions report, the most significant characteristics of zinc alloys are castability, resistance, hardness, dimensional stability, creep performance and suitability for surface treatments. Now we will see these properties in detail.

Castability

The four zinc alloys mainly used for hot chamber die casting have all an excellent castability: it is exactly this feature that makes them specifically suitable for hot chamber die casting. High castability levels allow the die caster to produce components characterized by very thin walls, which are lighter compared to components produced with other metals. This ability to obtain minimum thickness leads also to a remarkable saving in terms of costs.

Resistance and hardness

Zinc alloys with the highest resistance and hardness are Alloy 2 and ZA8. Alloy 2 indeed contains a high copper percentage that gives it a particular resistance, while ZA8, despite having a copper amount similar to that of Alloy 5, is more resistant and hard thanks to the extremely high aluminum percentage (8,0-8,8%). These two alloys are therefore perfect for the production of components that need a great resistance and hardness but do not require specific dimensional parameters.

Dimensional stability

On the contrary, products that need a high dimensional stability over time should be produced using Alloy 3 or Alloy 5. These two alloys have indeed the right copper percentage to ensure a good resistance, while at the same time assuring dimensional stability over time. They are an excellent choice for the production of components with very complex shapes that require minimum dimensional shrinkage in order not to compromise the functionality of the product as time goes by. Thanks to this balance between resistance and dimensional stability Alloy 3 and Alloy 5 are the most widely used zinc alloys respectively in North America and Europe.

Creep performance

As far as creep performance is concerned, the most efficient alloys are Alloy 2 and ZA8. However, also Alloy 5 has a good creep performance, superior to that of Alloy 3, consequently it is more suitable to be used at high temperatures under a continuous stress.

Surface treatments

All zinc alloys listed in this post are appropriate for surface treatments: high fluidity of ZAMAK allows the die caster to apply various kinds of finishes, from chroming to powder coating. Zinc components can be worked in order to achieve almost every type of surface finish desired, thus obtaining aesthetically appealing products thanks to a shining chrome finish or a painting with intense and vivid colors, as well as smooth and silky surfaces thanks to satin finishing.

How to choose the most appropriate zinc alloy

Ultimately, to choose the most appropriate zinc alloy for one’s own product it is essential to focus on two main concepts: which are the characteristics that the final product should have and which are the properties of the zinc alloy that are fundamental to achieve these characteristics. If the component must be specifically resistant because it will be exposed to a high stress during its life cycle, then it will be more advantageous to choose Alloy 2 or ZA8. On the contrary, if the component needs a high dimensional stability level because it has very narrow tolerances, then it will be more convenient to choose Alloy 3 or Alloy 5.

Each product has specific and unique technical features that must be carefully examined in order to identify the most suitable zinc alloy, thus enhancing as much as possible the final outcome. The die cast supplier is consequently a valuable help when looking for the best zinc alloy to use because, thanks to the experience gained in different sectors and to the deep knowledge of the raw material, he or she can give precious advice for the achievement of the requested performance.

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