Zamak 27
Zamak 27 is a premium zinc alloy designed for die casting that provides exceptional mechanical strength, superior corrosion resistance, and excellent dimensional stability. This alloy is particularly suitable for demanding automotive, industrial, and electronics applications, where high-performance, durability, and precision are essential. Zamak 27 is often preferred for heavy-duty applications where parts are exposed to mechanical stress and harsh environmental conditions.
At Neway, we specialize in Zamak 27 die casting solutions, offering advanced CNC machining, tooling, and surface finishing capabilities to ensure optimal strength, precision, and durability for your components.
Description
Zamak 27 is a high-performance zinc alloy known for its exceptional mechanical properties, corrosion resistance, and dimensional stability, making it ideal for precision die casting in heavy-duty applications.
Key Characteristics of Zamak 27
Zamak 27 is a zinc-aluminum-copper alloy with excellent mechanical properties, including enhanced strength compared to other Zamak alloys. Its high copper content increases tensile strength, wear resistance, and corrosion resistance. Zamak 27’s excellent fluidity allows it to fill intricate mold designs, making it suitable for complex, thin-walled parts.
Property | Value (Typical, As-Cast) |
|---|---|
Density | 6.7 g/cm³ |
Ultimate Tensile Strength | ~390 MPa (56,550 psi) |
Yield Strength | ~250 MPa (36,250 psi) |
Elongation at Break | ~1.5% |
Thermal Conductivity | ~115 W/m·K |
Coefficient of Thermal Expansion | ~22.5 µm/m·°C |
Brinell Hardness | ~90 HB |
Corrosion Resistance | Excellent (better than Zamak 3 and Zamak 5) |
Zamak 27’s excellent strength-to-weight ratio, superior corrosion resistance, and high dimensional stability make it ideal for high-performance, high-precision applications.
Chemical Composition of Zamak 27
Element | Composition (wt%) |
|---|---|
Zinc (Zn) | 94.5–96.0% |
Aluminum (Al) | 3.5–4.5% |
Copper (Cu) | 1.0–1.5% |
Magnesium (Mg) | ≤ 0.05% |
The increased copper content in Zamak 27 significantly enhances the alloy's mechanical properties, particularly its strength and wear resistance, while maintaining good fluidity for precise casting.
Mechanical Properties of Zamak 27 Zinc Alloy
Zamak 27 is engineered to perform under demanding conditions, offering high mechanical strength, superior fatigue resistance, and excellent dimensional stability. The following mechanical properties are typical for Zamak 27, in line with ASTM and JIS standards.
Property | Value (As-Cast) |
|---|---|
Ultimate Tensile Strength | ~390 MPa (56,550 psi) |
Yield Strength (0.2% offset) | ~250 MPa (36,250 psi) |
Elongation at Break | ~1.5% |
Fatigue Strength (10⁸ cycles) | ~150 MPa (21,750 psi) |
Modulus of Elasticity | ~70 GPa |
Brinell Hardness | ~90 HB |
Zamak 27’s high tensile strength and fatigue resistance make it ideal for parts exposed to mechanical and thermal stress over long periods, such as those used in automotive, aerospace, and industrial applications.
Benefits of Using Zamak 27 in Die Casting
High Strength: Zamak 27 provides superior tensile strength compared to Zamak 3 and Zamak 5, making it suitable for load-bearing applications in critical components.
Corrosion Resistance: The high copper content offers enhanced protection against corrosion, especially in outdoor or marine environments.
Superior Fluidity: Zamak 27 is known for its excellent casting fluidity, allowing it to produce complex, thin-walled parts with minimal porosity.
Dimensional Stability: Zamak 27 maintains precise dimensions even during high-volume casting, ensuring the production of high-precision parts.
Thermal Stability: This alloy performs well under high-temperature conditions, maintaining its mechanical properties without significant degradation.
Typical Applications of Zamak 27 Die Cast Parts
Zamak 27’s combination of strength, corrosion resistance, and dimensional stability makes it ideal for a wide range of applications that require durability and precision. Common uses include:
Automotive: Engine components, transmission parts, steering brackets, and structural elements
Industrial Equipment: Pump housings, valves, and high-stress machinery components
Consumer Electronics: Electrical enclosures, power tool housings, and connectors
Aerospace: High-strength precision components for mechanical systems and engine parts
Marine: Seawater-resistant fasteners, valves, pump casings, and outdoor enclosures
The durability and precision of Zamak 27 make it suitable for demanding environments where both performance and longevity are critical.
CNC Machining Considerations for Zamak 27
Zamak 27 is relatively easy to machine, but its higher copper content requires carbide tools to reduce tool wear and increase efficiency. The alloy’s excellent machinability and fine surface finish make it ideal for high-precision post-casting operations.
Machining Recommendations:
Tooling: Use carbide or TiAlN-coated carbide tools to minimize wear due to copper content.
Cutting Speed: Milling: 250–500 m/min; drilling: 100–150 m/min
Feed Rate: 0.05–0.15 mm/rev, depending on the complexity of the part and tool size
Coolants: Use water-based or synthetic coolants for optimal heat dissipation and improved tool life.
Surface Finish: Ra ≤ 1.6 µm achievable for precision and aesthetic finishes.
Tolerance: ±0.03 mm achievable for critical features.
Neway’s CNC machining services ensure high-precision and superior post-processing for Zamak 27 die-cast parts.
Surface Treatments for Zamak 27 Parts
Zamak 27 parts can undergo several surface treatments to enhance their performance and aesthetics:
Anodizing: Provides enhanced corrosion resistance and a variety of color finishes for decorative applications.
Powder Coating: Offers a protective layer and custom colors, ideal for outdoor or harsh environments.
Painting: UV-resistant coatings for parts exposed to sunlight or weathering.
Tumbling: Used to smooth surfaces and remove burrs before coating or assembly.
All treatments are rigorously tested for adherence, corrosion resistance, and long-term performance according to international standards like ASTM B117 (salt spray) and ISO 2409 (cross-cut adhesion).
Why Choose Neway for Zamak 27 Die Casting?
Neway provides comprehensive Zamak 27 die casting solutions, from design for manufacturability to high-volume production and precision CNC machining. We offer end-to-end services to ensure that your Zamak 27 parts meet the highest mechanical strength, durability, and dimensional accuracy standards.
FAQs:
How does Zamak 27 compare to Zamak 5 regarding strength and corrosion resistance?
Can Zamak 27 die cast parts be anodized or powder-coated for enhanced protection?
What industries commonly use Zamak 27 for precision die casting?
What machining techniques ensure the best results for Zamak 27?
How does Zamak 27 perform in high-temperature environments?
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