Alloys: Zamak 3 (ZL3, ZL0400, ZnAI4, alloy 3)
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Initially, the hub–two intersecting cylinders–was a brazed assembly. Cylinders were screw machined from solid brass. Operations included turning, drilling, internal milling, cut-off, and rolling of one cylinder end to accept a plastic transition piece. The redesigned...
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Ignition switch corrosion was the source of customer frustration and concern. Standard panel nuts, like the ones used to secure the ignition switch to the riding mower control panel, are made of stamped steel. The die cast company’s technical staff proposed changing...
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This chassis for a motor drive unit for an automatic opening roller door was made from several pressed metal parts prior to being designed as a zinc die casting. Die casting in zinc alloy 3 provided numerous benefits: 1.) Additional features such as pockets, the...
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Zinc die casting was chosen to reduce cost of an antenna base for mobile radio equipment, which was originally a brass screw-machined part. Powder metallurgy was evaluated, but it couldn’t achieve the required undercuts without machining. Zamak 2 alloy was specified...
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A four-piece miter gear assembly utilized zinc die casting for strength and precision. Both pinion gear shafts and housing halves are die cast net-shape, achieving full functionality without a cost penalty compared to alternative designs (thermoplastic housing/gears...
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