Casting Study: Corner Stake – Security Door

The zinc pressure die cast corner stake, fastened with pop rivets, fits tightly into the Galvabond roll form section of the door. It has to compete with plastic molded, aluminium extruded, and aluminium pressed parts’ this is because of the many properties of the zinc alloy and process. Very close dimensional tolerances are needed to give the right fit with the roll form. Flatness is also important, as small deviations would result in warps in the door section. It must also withstand the impact of slamming doors. Use of thin walls with ribbing gives the necessary strength while still being lightweight. Production on a fully automated hot chamber die casting machine at 400 shots per hour ensures cost competitiveness.