Die casting in zamak is a process that produces high-precision parts with an excellent combination of durability, strength, and detailing capability. However, after the initial injection, it is common for parts to require secondary operations to enhance their finish, functionality, and aesthetics. These secondary operations are essential to refine the final details of the parts and ensure they meet the specific demands of each application and industry.
This article discusses some of the most common secondary operations applied to zamak products, such as vibration, shot blasting, machining, and surface treatments. If your company needs zamak parts with customised features, the following operations can help achieve the desired results in terms of finish and performance.
Vibration: Removing Burrs and Enhancing Appearance
Vibration is one of the first secondary operations carried out after injection. During the casting process, small burrs may appear on the edges or surfaces of the part, which must be removed to improve both the functionality and aesthetics of the product. Vibration involves placing zamak parts in a container with abrasive media, usually ceramic or metallic components, and vibrating the entire assembly.
The vibratory motion allows the ceramic chips of different shapes, depending on the part, to remove burrs and polish the part’s surface, resulting in a smoother, more uniform finish. This operation enhances appearance and prepares the part for subsequent operations, such as surface treatment or machining. Vibration is beneficial when zamak parts require a uniform finish without altering the precise dimensional characteristics achieved during injection.
Shot Blasting: Refining the Surface
Shot blasting is a crucial operation for improving the surface of zamak parts. Similar to vibration, it aims to remove surface imperfections, such as burrs or minor irregularities but utilises a different method. In this process, a stream of abrasive shot made of steel, glass, or another material is blasted at high speed over the parts.
This shot's impact smooths and refines the surface, creating a matte or textured finish that enhances the aesthetics and the adherence to additional surface treatments, such as paint or coatings. Shot blasting is ideal for parts requiring a uniform surface ready for further finishing or for products needing greater surface strength, as the process also strengthens the outer layer of the material.
Machining: Creating Functional Details
Although zamak die casting can produce parts with complex details and high precision, additional machining operations are sometimes necessary. These include creating holes, grooves, threads, or other specific features that are not easily achieved during injection.
Machining is a material-removal process performed with specialised tools, such as milling machines or lathes, ensuring that zamak parts meet specific dimensional and functional requirements. In many cases, machining is essential to adapt parts for final assembly or to add features that enhance their performance in particular applications. These operations also allow for greater design flexibility, as parts can be modified post-casting to suit the evolving needs of projects.
Surface Treatments: Protection and Aesthetics
Once the parts have been vibrated, shot blasted, and, if necessary, machined, the final step in many applications is applying a surface treatment. Zamak is a material well-suited to a wide variety of surface finishes, allowing both appearance and protective properties to be tailored.
Among the most common treatments is painting, which can be applied by spraying, dipping, or electrophoresis. These methods allow for uniform, durable coverage, protecting parts against corrosion and enhancing their wear resistance. Paint provides a protective layer and enhances aesthetic finishes, from vibrant colours to specific textures.
Other surface treatments include chrome plating, nickel plating, or powder coatings, all designed to enhance the appearance and functionality of zamak parts in their final use. These treatments are essential in sectors where corrosion resistance and durability are critical, such as in electronic components or automotive parts.
Jegan: Manufacturing Zamak Parts for Various Industries
At Jegan, we specialise in zamak die casting and in applying secondary operations to ensure that each part meets the highest standards of quality and precision. From vibration and shot blasting to machining and surface treatments, we have the expertise and technology to deliver products tailored to your needs.
If you would like to learn more about how secondary operations can improve the quality and functionality of your zamak parts, In that case, we invite you to follow us on LinkedIn or contact us. At Jegan, we are committed to delivering high-performance, customised solutions for every project.
