High pressure die casting in zinc and alluminium alloys

What is high pressure die casting

High pressure die casting is a very precise forming technique in which molten zinc or aluminium is injected under high pressure into an extremely precise and high quality steel mould (the die).

It is the ideal technique to produce complex parts with high accuracy. The geometry and complexity determine the parts and quantities for which high pressure die casting is favorable.

Pedeo specialises in high pressure die casting, also known as injection moulding or foundry casting, in zinc and aluminium alloys.

Zinc alloys, also known as zamak or zamac, have a number of very interesting advantages because the parts can be casted with precision and thin-walled.

Aluminium casting largely has these same properties and in particular is lighter than zinc casting.

Discover the high pressure die casting process here

Aluminium

Zamak

Why high pressure die casting?

High pressure die casting of zinc and aluminium offers the following technical and economic advantages:

  • Efficient and precise casting technique for parts with high accuracy and clean surfaces
  • Finishing often unnecessary
  • Light, complex and thin-walled parts
  • Optimal use of raw materials
  • Integration of different functions through extensive freedom of form and complexity

Zinc and aluminium alloys

Pedeo High Pressure Die Casting foundry only uses European certified alloys:

  • Zinc alloys:
    • Zamak 5 (ZL-0410) – ZnAl4Cu1
    • Zamak 2 (ZL-0430) – ZnAl4Cu3
  • Aluminium alloys:
    • Alu231 (EN AC-47100) – EN AC-Al Si12Cu1(Fe)
    • Alu226 (EN AC-46000) – EN AC-AlSi9Cu3(Fe)

Comparative table of alloys

  Zamak 5
(ZL-0410)
Zamak 2
(ZL-0430)
Alu231
(EN AC-47100)
Alu226
(EN AC-46000)
Tensile strength (MPa min) 280-350 330-380 220-300 240-310
0.2% yield limit (MPa min) 220-350 310-350 140-240 140-200
Elongation at break (% min) 2-5 5-10  1-3 0,5-3
Hardness (Ha min) 85-105 100-130 60-100 80-120
Specific gravity (g/cm3) 6,7 6,8 2,65 2,75
Linear expansion coefficient (10-6 K) 27 27 21 21
Thermal conductivity (W/(m.K)) 0,92-1,05 0,92-1,05 1,2-1,4 1,1-1,3
Electrical conductivity (m/Ωmm2) 15-16 15 15-18 14-17
Galvanic surface treatment +++ +++ – – – – – –
Technical anodisation – – – – ++ ++
Machinability +++ +++ +++ ++
 Corrosion resistance ++ ++ ++ +

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