When we talk about die-casting, we refer to the manufacturing process by which metal parts with complex shapes and different types of strengths and tolerances are shaped by injecting molten metal into a mould under high pressure. Alloys used include aluminium, magnesium, and zinc. Zinc alloys are called zamak, the resulting alloy of zinc, aluminium, magnesium and copper.
The high capacity to produce elements with a high degree of precision differentiates die casting from traditional casting; it is also one of its main advantages. In addition, zamak die casting stands out for the different types of finishes that can be applied and their resistance to continuous use.
Types of die-casting
There are several die-casting types; the most common types are cold chamber die casting and hot chamber die casting.
In the cold chamber model, the furnace is not part of the machine and is injected horizontally in at least three injection phases. It is intended for high melting point non-ferrous alloys such as aluminium and brass.
Conversely, injection is done vertically in hot die casting, and the furnace is integrated. It is a faster method than the previous one, as the metal is ready for injection immediately and is very suitable for large-scale production. In this case, materials with a lower melting point, such as non-ferrous alloys, such as zamak (zinc), lead, or magnesium, are used.
Each of the two methods has its advantages, and the material mainly determines the choice of one or the other.
Basics of Zamak die-casting
Zamak die casting is a specific process involving the use of zamak and consists of the following steps:
- Feasibility study, mould design and choice of suitable alloy: in the first part of the process, a feasibility study is carried out to ensure that production will be feasible and profitable. At Jegan, this work brings engineers and the customer together so that all needs and requirements are considered to start production with guarantees. This decision is followed by designing the mould, one of the key steps, and determining the alloy to be used. Although zamak is a very versatile material, selecting the suitable alloy will evaluate the final product's performance.
- Die casting: the molten alloy is injected into the mould cavity or cavities under pressure. In addition, it ensures that the final part is in line with the drawing.
- Secondary operations: after Jegan's die casting, a series of secondary operations are performed to increase the quality and functionality of each component. Depending on requirements, vibratory or shot blasting is performed to remove burrs and improve appearance. Some parts undergo machining operations, and, if an aesthetic appearance or specific protection is required, a particular surface treatment is applied to the zamak injected part.
- Surface treatments: zamak die casting allows us to obtain elements with high-quality surface finishes, for which different types of metallic coatings are used, such as zinc, nickel or chrome plating, which, in addition to improving the appearance, increase its resistance to corrosion and/or enhance the fixation of the paint.
In addition, exhaustive quality controls are carried out during all stages of the process, with the goal of a zero-defect process.
At Jegan, in addition to the production process itself, two steps are added: specific packaging for industrial sectors, thinking about what best suits the customer's needs and paying particular attention to reducing the carbon footprint; and shipping to international markets, adapting the packaging to the needs of the customer and the destination.
Zamak die casting with Jegan: precision and versatility
Zamak die casting results in high batches, high repeatability and no dimensional variation. With one mould, up to one million injections can be obtained with minimal variation, so it has a competitive advantage for large-scale production, as the same mould and energy can be used to get robust parts with dimensional complexity, offering solutions for various sectors. Automotive, household appliances and electronics are just some of them.
At Jegan, we work to guarantee zamak solutions that adapt to each project's typology, needs and details. If you have any questions or would like to learn more, contact us and join our community on social networks.