• 压铸锌

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    Engineering in zinc, today’s answer

    工程锌,今天的答案

    Enhance Your Brand Product and Reputation:

    Engineered Zinc Die Castings for Optimal Design Freedom and Precision.

    提高您的品牌产品及声誉

    为了实现最佳设计自由度和精确度,对锌压铸进行改造

     

    The Advantages of Zinc Casting Alloys

    锌压铸合金的优点

    Zinc casting alloys are strong, durable and cost effective engineering materials. No other alloy sys­tem provides the combination of strength, toughness, rigidity, bearing performance and economical castability. Zinc’s mechanical properties compete with and often exceed those of cast aluminum, magnesium, bronze, plastics and most cast irons. These characteristics, together with their superior finishing capabilities and choice of casting process­es make zinc alloys an unrivaled material choice for saving time and money.

     

     

    锌压铸合金是一种坚固耐用且经济的工程材料。没有其他合金系统能提供如此强度、延展性、硬度、受力性能及经济性的组合。锌的力学性能与那些铸铝、镁、青铜、塑料及大多数的铸铁相比,通常超过它们。这些特性加上其卓越的精加工能力和铸造工艺的选择,使得锌合金成为节省时间和成本无可比拟的材料选择。

    Assembly operations are reduced. Entire assem­blies can be cast as a single unit, eliminating the need for expensive manual assembly operations.

    Less material is required. Zinc’s superior casting fluidity, strength and stiffness permits the design of thin wall sections for reduced weight and mate­rial cost savings.

    Machining operations are reduced. Due to the superior net-shape casting capability of zinc alloys, machining can be eliminated or drastically reduced.

    Faster production and extended tool life. Die cast‑

    ing production rates for zinc are much faster than for aluminum or magnesium. Coupled with a tool life often exceeding 1 million parts, tooling and machine usage charges are dramatically reduced.

    Eliminate bearings and bushings. Zinc’s excellent bearing and wear properties allow greater design flexibility and reduce secondary fabrication costs by eliminating small bushings and wear inserts.

    Choice of low, medium, and high production. A variety of casting processes are available to eco­nomically manufacture cast parts of whatever size and quantity required.

    Surface finishing. When a finish is properly selected and applied to cast zinc, almost any desired aesthetic characteristic and coating durability can be achieved.

    Environmental harmony. Pollution and greenhouse gases are minimized with zinc casting alloys.

     

    减少装配操作。整个组件可以作为一个单独的单元进行铸造,因而无需昂贵的手动组装操作。

    材料需求量少。锌具有优异的铸造流动性、强度和刚度,允许薄壁截面的设计以降低重量及节省材料成本。

    减少机械加工。因为锌合金具有优异的净形铸造性能,可以消除或大大减少加工。

    更快的生产并延长工具寿命。锌合金的压铸生产率比铝和镁要快得多,加上工具寿命通常超过100万件,工具和机器使用费用会大大降低。

    消除承载和衬套。锌优异的承载和磨损性能使设计更加灵活,并通过消除小的衬套和磨损来降低二次制造成本。

    选择低、中、高产量。各种铸造工艺可经济的制造各种尺寸和需求量的铸件。

    表面加工。适当的选择精加工并应用于铸造锌时,几乎可以实现任何期望的美学特性和涂层耐久性。

    环境和谐。使用锌压铸合金,将污染和温室气体排放最小化。

     

    Alloy tailored to meet your needs: general purpose and specialty alloys.

    订制的合金满足您的需求:通用和特种合金

    There are two basic families of zinc casting alloy. The conventional or ‘ZAMAK’ alloys are commonly named based on their sequential development, preceded by the word alloy. These include Alloy 2, Alloy 3, Alloy 5, and Alloy 7. The most recent addition to the ZAMAK family is the new high-fluidity or ‘HF’ al­loy. Zinc alloys with higher amounts of aluminum than the conventional alloys use the prefix ZA followed by their approximate aluminum content. These include ZA-8, ZA-12 and ZA-27. ZA alloys offer higher strength, and useful bearing properties.

    Several different systems of naming the two classes of zinc alloys have evolved along with them, as indi­cated in parenthesis next to the main alloy names below.

    锌压铸合金有两个基本家族,常规或’ZAMAK’合金通常以其发展顺序命名,前面是“合金”这个词。这些包括Alloy2, Alloy3, Alloy5,和Alloy7. 最新加入ZAMAK家族的是新的高流动性能或称HF合金。与传统合金相比,铝含量比较高的锌合金采用ZA作为前缀,后面是其近似的铝含量。这些包括ZA-8,ZA-12和ZA-27. ZA合金提供了更高的强度和有用的承载特性。

    几种不同的这两类锌合金命名系统跟随它们一起发展,如下面主要合金名称旁边的括号中所示。

    Major alloy characristics

    主要合金特性

    Alloy 3: (ZAMAK 3, ZP3, ZL3, ZP0400, ZnAl4, ZDC2) Alloy 3 is the most widely used zinc alloy in North America. Its popularity is due to an excellent bal­ance of desirable physical and mechanical prop­erties, superb castability and long-term dimen­sional stability. No. 3 also offers excellent finishing characteristics for plating, painting and chromate treatments. It is the “standard” by which other zinc alloys are rated in terms of die casting

    Alloy 5: (ZAMAK 5, ZP5, ZL5, ZP0410, ZnAl4Cu1, ZDC1) Alloy 5 is the most widely used zinc alloy in Eu­rope. No. 5 has excellent castability characteristics and improved creep performance over No. 3. No. 5 castings are also marginally stronger and hard­er than No. 3, however, these improvements are accompanied by a reduction in ductility that can affect formability during secondary bending, rivet­ing, swaging or crimping operations. No. 5 con­tains an addition of 1% copper which accounts for these property changes. When an extra measure of tensile performance is needed, No. 5 castings are recommended. The alloy is readily plated, fin­ished and machined, comparable to No. 3 alloy.

    Alloy 7: (ZAMAK 7, ZL7)

    Alloy 7 is a modification of No 3 with a lower magnesium content and tighter impurities spec­ification. This results in improved casting fluidi­ty, ductility and surface finish, making the alloy

     

     

    popular where the die caster is making thin walled components requiring a good surface finish. How­ever, several new high fluidity alloys have recently been developed with superior thin wall character­istics (see high fluidity alloy).

    Alloy 2: (ZAMAK 2, ZP2, ZL2, ZP0430, ZnAl4Cu3, Kirksite) Alloy 2 offers the highest strength and hardness of the conventional zinc alloys. The high copper content (3%) in No. 2 results in property changes upon long-term aging. These changes include slight dimensional growth, lower elongation and reduced impact performance (to levels similar to aluminum alloys) for die cast products. No. 2 alloy exhibits excellent castability and maintains higher strength and hardness levels after long term aging. No. 2 alloy is a good bearing material, and may eliminate bushings and wear inserts in die cast designs.

    High Fluidity Alloy: (HF)

    The HF alloy shares the good mechanical, electric and thermal conductivity property characteristics of the conventional alloys but possesses up to 40% better fluidity. Because of its optimization of composition for high fluidity, the HF alloy s best suited for casting parts with section thickness less than 0.45 mm. It can also be used for casting parts that are difficult to fill with Alloy 3, 5 or 7 or have high surface finish requirements.

    Alloy3: (ZAMAK3, ZP3, ZL3, ZP0400, ZnAl4, ZDC2)

    Alloy3是北美是最广泛应用的锌合金。它受欢迎是因为理想的物理和机械性能完美的平衡, 杰出的铸造性能和长期的尺寸稳定性。NO.3同样对于电镀、油漆、铬酸处理方面具有优良的加工性能。它是其他锌合金在压铸方面的“标准”。

    Alloy5 (ZAMAK5, ZP5, ZL5, ZP0410, ZnAl4Cu1, ZDC1)

    Alloy5是欧洲应用最广泛的锌合金。NO.5有优良的铸造性能和优于NO.3的蠕变性能。NO.5铸件也略有加强,比NO.3更坚硬。然而这些改进伴随着延展性的降低,会对二次弯曲,铆接,旋锻或压接操作期间的成型性产生影响。NO.5含有1%的铜,这都是这些性质变化的原因。当需要额外测量拉伸性能时,推荐使用NO.5铸件。该合金易于电镀、精加工、加工,可与NO.3相媲美。

    Alloy7: (ZAMAK7, ZL7)

    Alloy7是一种NO.3的改良,具有较低的镁含量和更严格的杂质规范。这改善了铸造流动性、延展性、表面处理效果,使合金在模具中很受欢迎,因为铸模铸造的薄壁零件需要很好的表面抛光。然而,最近有几种新型的高流动性能合金已经开发出优异的薄壁特性。(详见高流动性能合金)

    Alloy2: (ZAMAK2, ZP2, ZL2, ZP0430, ZnAl4Cu3, kirksite)

    Alloy2是传统锌合金中具有最高强度和硬度的合金。NO.2中较高的铜含量(3%)导致了长期老化过程中,特性的变化。这些变化包括了:压铸产品微小尺寸的增长,更低的延伸率,并且降低冲击性能(水平近似于铝合金)。NO.2合金显示出优异的铸造性能并且在长期老化后能维持较高的强度和硬度水平。NO.2合金是一种较好的承载材料,且可以在压铸设计中消除衬套和磨损。

    高流动性能合金(HF

    HF合金与传统合金一样具有良好的机械、电气和导热性能,但它具有高达40%更好的流动性能。由于其高流动性成分的优化,HF合金是最适合用于截面厚度小于0.45mm的铸件。它也可以用于alloy3,5,7都难以满足或高表面处理需求的铸件。

     

    ZA-8: (ZP8)

    A good gravity casting alloy, ZA-8 can also be hot chamber die cast and is readily plated and finished using standard procedures for conventional zinc alloys. When the perfor­mance of Alloys No. 3 or No. 5 is in question, ZA-8 is often the die casting choice because of high strength and creep properties and efficient hot chamber castability.

    ZA-12:

    ZA-12 is the best gravity casting alloy for sand, permanent mold and the graphite mold casting process. It is also a good (cold chamber) die casting alloy. ZA-12 often com­petes with ZA-27 for strength applications. An excellent bearing alloy, ZA-12 is also platable, although plating adhe­sion is reduced compared to the conventional zinc alloys.

    ZA-27: (ZP27)

    This is an exceptionally strong alloy with a reported yield strength of 380 MPa (55ksi). It is light, and has excellent bear­ing and wear performance. Like ZA-12, this is a cold chamber die casting alloy and additional care is needed to ensure a sound casting. ZA-27 is not recommended for plating. When brute strength or wear resistance properties are needed, ZA­27 has demonstrated excellent performance.

    ACuZinc5:

    Developed by General Motors, this alloy has improved ten­sile strength, hardness and creep performance compared to the conventional zinc alloys. ACuZinc5’s strength and hardness properties are comparable to ZA-12. Testing has also shown ACuZinc5 to have excellent wear characteristics. Although this alloy is a hot chamber die casting alloy, it is more difficult to die cast with a higher wear rate of the shot end components in the die casting machine.

    EZACTM:

    This recently developed alloy is the most creep resistant of all the zinc die casting alloys with an order of magnitude improvement over Alloy 5 and ZA-8. This is also a very strong alloy with a yield strength 393 MPa (57 ksi) and hardness (102-140 Brinell) comparable to ZA-27. Due to its low melting temperature, EZAC can be hot chamber die cast and does not exhibit the same die casting equipment wear and tear as shown with ACuZinc5.

    GDSL: (Superloy)

    Guss-Druck-Sonderlegierung “GDSL” is an ultra-thin zinc die casting alloy with fluidity characteristics similar to the HF alloy, but with a higher aluminum and copper content.

    TM. A trademark or Eastern Alloys

     

    ZA-8 (ZP8)

    一种良好的重力铸造合金,ZA-8也可以热室压铸,并且它易于用传统锌合金的标准工序进行电镀和表面处理。当NO.3或NO.5合金性能有问题的时候,由于高强度、蠕变性能和高效的热室铸造性,ZA-8通常会成为压铸的选择。

    ZA-12:

    ZA-12是砂型、永久铸模和石墨模具铸造工艺中最好的重力铸造合金,它也是一种良好的(冷室)压铸合金。ZA-12在强度应用方面能与ZA-27相比拟。一种优异的承载合金,ZA-12也可电镀,虽然与常规的锌合金相比,电镀附着力有所下降。

    ZA-27(ZP27)

    这是一种据说有380MPa(55ksi)屈服强度的超强合金。它很轻,且具有优异的承载和磨损性能。如ZA-12合金,它是一种冷室压铸合金,需要额外的保养来确保一种致密铸件。ZA-27不适用于电镀。当需要强力和耐磨性能时,ZA-27表现出优异的性能。

    ACuZinc5:

    由通用汽车开发,与传统锌合金相比,这种合金在拉伸强度、硬度和蠕变性能方面都有所提高。ACuZinc5的强度、硬度可与ZA-12相媲美,测试也同样可以显示ACuZinc5具有优异的磨损特性。虽然该合金是一种热室压铸合金,但是在压铸机中以更高的磨损速率对喷射端部件进行压铸更难。

    EZACTM

    最新开发的合金是所有锌压铸合金中抗蠕变性最好的,比Alloy5和ZA-8提高了一个改善幅度。它也是非常强的合金,屈服强度为393MPa(57ksi)与ZA-27相当的硬度(102-140Brinell)。因为其具有比较低的熔点,EZAC可以热室压铸,且不会出现与ACuZinc5所示相同的压铸设备磨损和撕裂。

    GDSL (Superloy)

    Guss-Druck-Sonderlegierung”GDSL”是一种超薄锌压铸合金,它有与HF合金相似的流动性能,但其具有较高的铝和铜含量。

     

    Material properties that help solve today’s engineering problems.

    材料特性,它可以帮忙解决今天的工程问题

    Strength

    The Ultimate Tensile Strengths (UTS) of zinc alloys can outperform Aluminum 380 and Magnesium AZ91D. Engineering Plastics struggle to deliver equivalent performance of zinc alloy’s UTS. Even glass-reinforced Nylon cannot achieve zinc alloy’s UTS. Ambient temperature Yield Strengths of zinc alloys are far superior to those of Aluminum 380, Magnesium AZ91D and the strongest plastics. Zinc alloys also display a high degree of energy absorbing ductility when subjected to abusive or destructive levels of loading.

     

    强度

    锌合金的极限拉伸强度(UTS)可以优于铝380和镁AZ91D。 工程塑料难以实现与锌合金UTS相当的性能,甚至玻璃增强尼龙也不能达到锌合金的UTS。 锌合金的温室屈服强度要远胜于铝380,镁AZ91D和最强的塑料。锌合金在受到滥用或破坏的程度时,也显示出高度的能量吸收延展性。

    Rigidity

    Zinc alloys are rigid engineering materials. Their strength - in shear, torsion, under bending and in compression - is far superior to aluminum, magne­sium and plastics. This combined with their high strength allows the volume of individual castings to be markedly reduced, saving space and weight.

     

    硬度

    锌合金是刚性工程材料。它们在剪切、扭转、弯曲和压缩方面的强度远远优于铝、镁和塑料。这与它们的高强度相结合,可以显著减少单个铸件的体积,节省空间和重量。

    Toughness and Ductility

    High impact strength and good ductility are qualities of zinc alloys that are rarely found in most other casting alloys. Ductility is important for bending and crimping in post-casting assem­bly operations, while impact strength provides performance in rough environments. At normal ambient temperatures, zinc die castings have a much greater impact resistance than Aluminum 380 and Magnesium AZ91D, and ABS plastics. At minus 30ºC zinc alloys still remain far better. Even at minus 40ºC zinc at least matches the impact resistance of die cast aluminum. Zinc alloys frac­ture toughness is also superior to most aluminum alloys and engineering plastics.

    韧性和延展性

    高冲击强度和良好的延展性是大多数其他铸造合金中很少发现的锌合金的特性。延展性对于后铸造组装操作中的弯曲和压接是很重要的,而冲击强度在恶劣环境中提供了性能。在常规的环境温度中,锌压铸有比铝380、镁AZ91D和ABS塑料更大的抗冲击性。在零下30℃下,锌合金依然好很多,甚至在零下40℃下,锌的抗冲击性至少和压铸铝相当。锌合金的断裂韧性也优于大多数铝合金及工程塑料。

    Hardness

    Zinc alloys are significantly harder than aluminum and magnesium. Alloying additions such as cop­per, contribute to the good wear resistance exhib­ited by zinc alloys. Hence these alloys are used in moderately demanding applications where their natural bearing properties can be exploited

    硬度

    锌合金明显比铝和镁更坚硬。合金添加剂如铜有助于锌合金表现出良好的耐磨性。因此这些合金被应用在要求适当的应用中,它们的天然承载性能可以被利用。

    Conductivity

    As zinc alloys conduct both heat and electricity, they can be used for heat dissipating devices such as heat sinks. Zinc’s excellent casting fluid­ity permits thinner fin and cooling pin design to better dissipate heat. Zinc’s excellent electrical conductivity also provides good EMI, RFI and ESD shielding.

    导电率

    由于锌合金既可导热又可导电,它们可以被用于散热装置,如散热片。锌的优异的铸造流动性允许更薄的翅片和冷却销设计,以更好地散热。锌优异的导电性也提供了良好的EMI,RFI和ESD屏蔽。

     

    Non-sparking and non-magnetic

    All zinc alloys except ZA-27 are classified as “non-sparking” and are the perfect low-cost alter­native to bronze in potentially explosive environ­ments. Unlike plastics and some other materials, zinc will not normally sustain fire during process­ing or use. It is a relatively fire safe material. Zinc’s non-magnetic properties are ideal for use in electronics and other applications where delicate moving parts are subject to magnetic disturbances.

    无火花和非磁性

    除了ZA-27以外,所有的锌合金被归类为“无火花”,并且在潜在的爆炸环境中青铜的完美的低价替代品。与塑料和其他材料不同的是,锌在加工或使用期间通常不会发生火灾,它是相对安全的防火材料。锌的非磁性特性在电子和其他微妙的移动部件会受到磁干扰的应用中是很理想的。

    Fatigue Strength

    This measure of a material’s ability to withstand cyclic loading is an important design criterion. Fatigue is one of the most frequent failure mech­anisms in components. Zinc, like other die cast metals is between 7 to 10 times more resistant to fatigue than ABS.

    疲劳强度

    这种材料抗循环荷载的能力是一个重要的设计准则。疲劳是组件中最常见的故障机制之一。锌和其他的压铸金属一样,抗疲劳的强度是ABS的7到10倍。

     

    Design (Creep) Stress

    For applications involving continuous loading at elevated temperatures, such as locks, zinc has su­perior creep strength to reinforced injection mold­ed plastics. The room temperature design stress of die cast ZA-27, as defined by the ASME Boiler Code, is 69 MPa or 10,000 psi (stress required for creep of 1% in 100,000 hours). This property al­lows zinc alloys to be used in applications subject to significant static loading. However, permissible design stress drops with increasing temperature and a careful review of all constant load applica­tions at temperature is required to determine the suitability of zinc alloys.

    设计(蠕变)应力

    对于涉及在高温下连续负载的应用,如锁,锌对增强的注射成型塑料具有优异的蠕变强度。按ASME锅炉规范中的定义,压铸ZA-27的室温设计应力应是69MPa或100,000psi(在10万小时内需要1%的应力)。这一特性使得锌合金可以应用于具有显著静态负载的应用场合。然而,允许的设计压力随着温度的升高而下降,并且对所有在温度上的恒定负荷应用进行仔细的评估,以确定锌合金的适宜性。

     

    Pressure Tightness

    The soundness of castings is largely related to product design, tooling layout, and process control. The tight tolerance levels of zinc alloys provide reliability and consistency required for pressure tight applications.

    气密性

    铸件的可靠性主要与产品设计、工具布局和工艺控制有关。锌合金的耐受力等级为压力紧密的应用提供了可靠性和一致性。

     

    Damping Capacity

    The damping capability of zinc alloys - their abil­ity to absorb energy and sound caused by exter­nally induced mechanical vibration - is compara­ble to magnesium, and is 5 to 10 times greater

    than aluminum. This property makes zinc alloys the perfect choice for housings where vibration absorption is required.

    阻尼性能

    锌合金的阻尼性能——它们吸收由外部引起的机械振动引起的能量和声音的能力——与镁相当,比铝大5到10倍。该特性使锌合金成为需要进行振动吸收的住宅的最佳选择。

    Corrosion Resistance

    Zinc has excellent corrosion resistance under normal atmospheric condiitons, and in many aqueous, industrial and petroleum environ­ments. Corrosion resistance can be enhanced by such treatments as plaitng, chromaitng, painitng and zinc anodizing.

    耐腐蚀性

    锌在常规的大气条件下,许多水、工业、石油环境下具有优异的耐腐蚀行性能,通过电镀、镀铬、涂漆、锌阳极氧化等处理,可以提高抗腐蚀性能。

     

    Super bearing properties ensure built-in reliability

     

    All zinc alloys, particularly ZA-12 and ZA-27, demonstrate excellent bearing and wear resistance qualities thanks to their high hardness and natural lubricity char­acteristics. ZA alloy bearings should be considered wherever bronze bearings are currently being specified. They generally operate best in lubricated, high-load, low-speed applications under moderate temperature conditions, however they have also been successfully used in high speed, low load applications.

     

    ZA alloys are direct substitutes for larger bronze industrial bushings and bearings since they cost less and are up to 43% lighter. For smaller components, zinc’s nat­ural lubricity may contribute to lower secondary fabrication costs by eliminating small bushings and wear inserts, thus allowing greater design flexibility.

    优越的承载特性确保内置的可靠性

    所有的锌合金,尤其是ZA-12和ZA-27都展示出了优异的承载和耐磨特点,这源于其高硬度和自润滑性。ZA合金承载应考虑当前青铜承载的位置。在适度的温度条件下,它们通常在润滑、高负荷、低速的应用中运行良好,但它们也在高速、低负荷的应用中得到了成功的应用。

    由于成本更低且重量轻了43%, ZA合金是更大的青铜工业衬套和轴承的直接替代品。对于较小的部件,锌的自然润滑可能通过消除小的衬套和磨损,从而降低二次制造成本,提高设计的灵活性。

     

    Engineering characteristics that answer your most critical needs. 工程特性,即回答你们最关键的需求

    Accuracy

    Zinc alloys are castable to closer tolerances than any other metal or molded plastic. Zinc die casting can produce repeatability of less than ± 0.001” for small components, often rivaling machining tolerances. Few other processes can easily achieve the same net shape performance presenting the opportunity to reduce or eliminate machining. “Net Shape” or “Zero Machining” manufacturing is a major advantage of zinc casting

    .精确性

    锌合金是浇注料比其他任何金属或模塑塑料更接近公差。锌压铸可生产低于±0.001的重复性。适用于小零件,具有较高的加工公差。很少有其他的工艺能够很容易地实现相同的净形状性能,从而减少或消除机械加工。“净成形”或“零加工制造”是锌铸造的主要优点。

    Machinability

    Fast, trouble-free machining characteristics of zinc materials minimize tool wear and machining costs which is a major advantage of zinc alloys over competitive materials.

    Thin Wall Capability

    Exceptional casting fluidity is displayed by all con­ventional zinc and ZA alloys, which provides supe­rior thin-wall castability, regardless of the casting process employed. Wall thicknesses of 0.15mm for die casting and 2.3mm for permanent mold casting are being produced. This thin-wall capabil­ity results in smaller, lighter, low cost components compared to other metals.

    机械加工性能

    锌材料的快速、无故障加工特点,使刀具磨损和加工成本降低,是锌合金在竞争材料方面的一大优势。

    薄壁能力

    所有传统锌合金和ZA合金都显示出优越的铸造流动性能,不管采用何种铸造工艺。它都可以提供优异的薄壁铸造性。生产的压铸用0.15mm的壁厚,永久模具铸造采用2.33mm。与其他金属相比,这种薄壁能力可以产生更小、更轻、成本更低的组件。

    Zero Draft Angle Castability

    Draft angle is the taper on the surface of a die required to facilitate removal of the cast part from the die cavity. Zinc alloys can be die cast with less draft angle than competitive materials. In fact, zinc components can sometimes be cast with zero draft angles which is a major advantage when pro­ducing parts in moving mechanical contacts such as gears. Zero internal draft permits net shape manufacturing resulting in lower cost production.

    零脱模角度铸造能力

    脱模角度是模具表面上的锥度,以便于将模具从模腔中移出。 锌合金可以与竞争性材料相比具有较小的脱模角度的压铸。 事实上,锌组件有时可以以零脱模角铸造,这是在移动机械接触件如齿轮时生产零件时的主要优点。 零内部脱模允许净形状制造,从而降低成本生产。

    Joining

    If required, the high ductility of zinc will allow parts to be distorted in a controlled manner to achieve a final desired shape, or be inexpensively joined to an adjacent component through bending, forming, spinning or heading. Threaded fasteners, along with flaring, riveting and crimping techniques are common low cost joining methods. Zinc alloys can also be joined using adhesive bonding or MIG and TIG welding, although welding is normally not an economical joining method for zinc die castings due to the high production volumes involved.

    焊接

    如果需要的话,锌的高延展性将会以控制的方式被扭曲,以达到最终的形状,或者通过弯曲、成形、旋转或的方式低价的接合到相邻的部件中。螺纹紧固件,以及扩口、铆接和压边技术是常见的低成本连接方法。锌合金也可以用粘接剂或MIG和TIG焊接接合,尽管由于所涉及的高生产量,焊接通常不是锌压铸件的经济连接方法。

    Dimensional Stability

    Conventional zinc alloys, along with ZA-8 and ZA-12, have excellent dimen­sional stability characteristics in their ‘as cast’ condition. ZA-27, however, may require artificial aging treatment to minimize aging effects where exceptional tolerances are required. This is accomplished by heating the part to 95°C for 24 hours.

    尺寸的稳定性

    常规的锌合金,以及ZA-8和ZA-12,在其“铸态”的条件下,都有优异的尺寸稳定性的特征。然而ZA-27可能需要人为的老化处理,以最大限度地减少需要特殊耐量的老化效应。这是通过将部分加热到95℃ 24小时来完成的。

     

    The Variety of high quality surface finishes is another major advantage.

    When clever design is combined with the versatility of the zinc die casting process, it maximizes the aesthetic appeal of products.

    多种高质量的表面处理是另一个主要优势

    巧妙的设计结合了锌压铸工艺的多功能性,使产品的美观性具有了最大的价值。

    Zinc die castings are an outstanding choice for countless decorative and functional applications. Due to its unique physical and mechanical properties, zinc can be cast into virtually limitless shapes and sizes ranging from simple toy cars to complex connector housings.

    对于无数的装饰及功能应用来说,锌压铸是杰出的选择。由于其独特的物理和机械性能,锌可以被铸造成为几乎无限制的形状和尺寸,从简单的玩具汽车到复杂的连接器外壳。

    The majority of zinc die cast applications are not exposed to corrosive environments and the aesthetic requirements of the part defines which finish should be used, which in many cases means no finish at all

    锌压铸件的大多数应用都不会暴露在腐蚀环境中,而部件的美学要求也决定了应该使用哪一种漆面,在很多情况下,这种要求根本就没有完成。

    For applications where the service environment is aggressive, or where aesthetics dictate, an unrivaled range and quality of conversion coatings, organic paint and superb electroplated metal finishes (e.g. nickel, satin and bright chrome) can be easily and reliably applied to any selected surfaces of your component.

    对于服务环境具有侵略性的应用,或美学要求的应用场合,不可比拟的范围和高质量的转换涂料,有机涂料和极好的电镀金属镀层(如镍、缎面和亮铬)可以很容易和可靠地应用于你的组件的任意选择的表面。

    Excellent substrates help yield excellent finishes. Inexpensive bulk vibratory finishing can be used to improve the ‘as cast’ surface. Exceptionally smooth finishes can be obtained prior to finishing by lightly buffing or chemical polishing.

    优秀的基底有助于生产出优异的表面,廉价的体积振动精加工可以应用于改善“铸型”表面。在轻巧的抛光或化学抛光进行精加工前可以获取异常光滑的表面。

    Due to the high fluidity of zinc alloys, a precisely defined surface texture can be added to part or all of the ‘as cast’ product. As a result, zinc castings can be made to look like solid gold, weathered brass, stainless steel, and even leather. Other external features such as lettering and logos can be ‘cast in’.

    由于锌合金较高的流动性,可以将精确定义的表面纹理到部分或所有“铸型”产品中。因此锌压铸件可以看起来像纯金、风化的黄铜、不锈钢,甚至皮革。其他外部特种例如字体及标识可以被“镶铸”。

    Zinc alloy’s density and its counter pointing ability to be very thinly cast allow the designer to influence

    the user’s perception of weight, balance, solidity and inertia. For instance, coolness in hand, a premium

    quality metallic feel and other perceived sensations are fac­tors valued by many users of zinc die castings. On the other hand, ‘warm feel’ coatings and plastic over-molding are also tactile options that the design­er can utilize.

    For maximum impact and success, the designer is ad­vised to consult the die caster at an early stage to agree on the best way of designing an economical and aesthetically attractive product

    锌合金的密度和其计数能力非常薄,使设计师能够影响用户对重量、平衡、稳定性和惯性的感知。例如,手感凉爽,金属质感和其他感知的感觉是许多锌压铸件的使用者所看重的因素。另一方面,“暖感”涂料和塑料过度成型也是设计师可以利用的触觉选择。

    为了达到最大的效果和成功,设计师建议在早期阶段咨询模具设计人员,以达成设计经济和美观的产品的最佳方式。

    Casting versatility leads to further savings.

    铸造的多样性使得进一步节省成本

    Process Flexibility: Virtually any casting process can be used with zinc alloys to satisfy any quantity and quality requirement. Precision, high-volume die casting is the most popular casting process. Zinc alloys can also be economically gravity cast for lower volumes using sand, permanent mold, graphite mold and plaster casting technologies.

    工艺机动性:实际几乎任何上各种铸造工艺都可以和锌合金一起配合使用,以满足质量和数量上的需求。精度、高产量压铸是最受欢迎的铸造工艺,锌合金也可以经济地重力铸造用

    沙子、永久铸模、石墨模和石膏铸造技术来降低产量。

    Die Casting

    This is the most efficient process for high-volume precision casting, producing the best tolerances and rapid production rates, but having high initial tooling costs.

    Die casting should be considered for components requiring a production run of at least 10,000 pieces. All tolerances depend on part size and complexity; however, tolerances of ± 0.025mm (0.001”) are common. Hot chamber die casting cycle rates range from roughly 150 parts per hour for large components to over 2000 per hour for small ones.

    The traditional zinc alloys and ZA-8 can be used in a “hot chamber” die casting machine, while ZA-12 and ZA-27 must be “cold chamber” die cast - like the aluminum alloys. The hot chamber process offers faster cycle times, resulting in lower production costs.

    Due to the low melting temperatures of zinc alloys, dies for zinc parts last longer—often 3-4 times longer than the same dies when used for casting aluminum alloys

    压铸

    这是高产量的精密铸件最有效的工艺,可以生产出最佳公差及快速生产率,但需很高的初始模具成本。

    对于需要生产至少1万件部件的,应考虑压铸。所有的公差依赖于零件的尺寸和复杂性;然而,±0.025mm(0.001”)的公差是正常的,热室压铸周期率范围从大致上大件的每小时150件到小件的每小时超过2000件。

    传统的锌合金和ZA-8可以用于“热室”压铸机上,而ZA-12和ZA-27必须进行“冷室”压铸-如铝合金。热室工艺提供较快的循环时间,从而降低生产成本。

    鉴于锌合金的融化温度较低,锌部件的铸模时间较长,通常比用于铸造铝合金相同的铸模时间长3-4倍。

    Permanent Mold Casting

    ZA-8 and ZA-12 are generally considered for permanent mold applications. Permanent mold casting has traditionally been done using steel or cast iron molds, but is now also performed in graphite molds. Per­manent mold casting often competes with sand casting by providing tighter tolerances and a smoother surface finish, which can reduce machining operations.

    Ferrous permanent molds designed for aluminum alloys are generally suitable for casting zinc alloys. However, due to the superior casting fluidity of zinc, thinner sections can be cast. This process is well suited for medium production runs of 500-10,000 pieces. Ferrous permanent mold casting has great flexibility in terms of part size, ranging from ounces up to 100 lbs.

    Graphite permanent mold casting offers some distinct advantages over metal tooling. Improved toler­ances, lower tooling costs, and a supe‑

    rior surface finish are all benefits of the graphite mold process. Drawbacks are limited component size, complexity and coring.

    金属型铸造

    ZA-8和ZA-12在一般考虑在金属模中应用。金属模具传统上使用钢或铸铁模具铸造,但现在也采用石墨模具。金属型铸造通常与砂铸进行比较,其可提供更严谨的公差和更光滑的表面处理,以减少机械加工。

    为铝而设计的铁金属型模具一般适用于铸造锌合金。然而因为锌较好的铸造流动性,可以铸造比较薄的部分。这种工艺很好的适用于中等产量500-10,000件产品的生产。铁金属型模具铸造在零件尺寸方面具有良好的灵活性,从盎司到100磅不等。

    与金属加工相比,石墨金属型铸造有明显的优势。改进的公差,较低的加工成本,以及表面处理都是石墨模具工艺的优点。缺点是组件的尺寸有限、复杂性和取芯。

    Sand Casting

    All the ZA alloys are suitable for sand casting; however, ZA-12 is the most popular. Sand casting offers the great­est design flexibility in terms of size, complexity and quantity requirements. Tooling costs are generally low, therefore facilitating low volume production. How­ever, surface smoothness and tolerance capabilities are limited, usually requiring machining.

    砂铸

    所有的ZA合金均适用于砂铸,然而ZA-12是最受欢迎的。在尺寸、复杂性和数量需求方面,砂铸提供了最好的设计灵活性。加工成本通常不高,所以促进了小批量生产。但是表面不够光洁,且公差成能力有限,一般需要加工。

    Hot chamber zinc die casting offers minimum processing cost.

    Production time savings

    This process combined with the relatively low casting temperature needed for zinc alloys allows excep­tionally high production rates. For medium sized zinc components, 400 to 1000 shots per hour are com­mon. Extremely small detailed zinc castings can be produced at up to 3500 shots per hour on specialized machines. By comparison, typical shot speed ranges for medium sized aluminum, magnesium and plastic components from 100 to 250, 200 to 300 and 100 to 300, respectively.

    Energy savings

    For an equal number of same size die castings, aluminum will use at least 50% more energy than zinc, while magnesium will need at least 15% more energy per casting than zinc. This is in addition to the high energy requirements needed to produce the aluminum and magnesium.

    Near Net Shape castings

    Clever design of product and tool, combined with zinc alloy’s inherent accuracy and excellent surface, can result in Near Net Shape zinc castings that require, if any, just the minimum of further processing stages.

    Low tooling wear

    For large volumes, zinc offers considerable further cost savings because its tooling typically lasts be­tween 750,000 shots to 2 million shots. Aluminum and magnesium will struggle to achieve 250,000 and 500,000 shots respectively.

    Hot Chamber Zinc Die casting is the most cost efficient production technique for 3D components due to its production speed and the low volume of scrap produced.

    热室锌压铸提供最小的工艺成本

    节省生产时间

    这一工序结合相对较低的锌合金所需的铸造温度,使得生产效率特别高。对于中等大小的锌零件,每小时400到1000次是很常见的。在专业的机器上每小时可以生产高达3500次的特别小精细的锌铸件。中等大小的铝、镁和塑料组件的典型压射速度分别为100到250、200到300和100到300。

    节省精力

    对于等量的相同大小的压铸件,铝的能量要比锌多至少50%,而镁则需要比锌多15%的能量。这不仅是生产铝和镁所需的高能耗需求。

    接近净形的铸件

    产品和工具的巧妙设计,加上锌合金固有的精度和优异的表面,可以致使接近要求的净形状的锌铸件,如果有的话,只需最少的进一步加工阶段。

    低工具磨损

    对于大产量来说,锌提供了相当大的成本节省空间,因为它的工具在75万到200万次之间,非常耐用。铝和镁将分别达到25万和50万次。

    热室锌压铸是3D组件生产速度快,生产量低的最有效的生产技术。

     

    Resource Efficient

    Pollution and greenhouse gases are minimized with zinc die casting:

    资源节约

    锌压铸的污染和温室气体最小化:

    Negligible emissions to air, land and water.

    Much smaller energy consumption than comparable alternative mass manufacturing processes.

    Any ‘scrap’ product from processing can be recycled.

    空气、土地和水的排放可以忽略不计。

    比可替代的大规模生产工艺要小得多。

    任何加工的废料都可以回收利用。

    Zinc alloys, as defined by international chemical composition standards, comfortably conform to the requirements of the End of Life Vehicle (ELV), Restriction of Hazardous Substances (RoHS) and Waste Electrical and Electronic Equipment (WEEE) legislation.根据国际化学成分标准定义的锌合金,完全符合报废汽车标准(ELV)、关于限制在电子电器设备中使用某些有害成分的指令(RoHS)和报废的电子电气设备(WEEE)法规

    Zinc die castings are premium quality low cost products that are highly resilient to many hostile condi­tions. They display considerable corrosion and wear resistance thus resulting in very long and reliable service, frequently measured in decades, and saving resources by not needing to be frequently replaced.

    A recycling infrastructure is actively in place to treat today’s zinc processing scraps and tomorrow’s end of life cast zinc alloy products. Zinc castings can be marked with ISO recycling mark as featured in EN 12844 for easy alloy recognition and future recycling

    锌压铸件是优质的低成本产品,具有很强的抗氧化能力。它们显示了相当长的腐蚀和耐磨性,因此产生了非常长的、可靠的服务,并且在几十年里经常被测量,并且不需要经常更换它们就可以节约资源。

    回收利用基础设施正在积极对待今天的锌加工废料和未来的铸造锌合金产品。 锌铸件可以标记为EN124444中的ISO回收标记,以便于合金识别和未来回收。

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