Zamak Die Casting: What It Is and How It Works

At Gurelan, Zamak parts are manufactured using hot-chamber die casting, a process that makes it possible to produce parts of different sizes, weights and for a wide range of applications.

What is Zamak?

Zamak is an alloy whose main component is zinc and which also contains aluminium, magnesium and copper.

Its name comes from the German initials of the elements that make up the alloy: Z for zinc, A for aluminium, MA for magnesium and K for Kupfer, copper.

At Gurelan, we work with Zamak 5, designated as ZP5 according to UNE-EN 12844 and as ZnAl4Cu1-ZL5 according to UNE-EN 1774.

The physical properties published by Gurelan for this alloy include:

• Density at 20 °C: 6.7 g/cm³.
• Melting range: 380–386 °C.
• Casting temperature: 410–430 °C.

How does Zamak die casting work?

For the manufacture of Zamak parts, Gurelan uses the hot-chamber die casting process.

This system can be used with alloys that melt at relatively low temperatures, such as zinc alloys.

Zamak ingots are melted in a furnace located next to the die casting machines. Once molten, the material is precisely injected to fill the mould cavity and obtain the required geometry of the part.

The fluidity of Zamak and its behaviour during the process make it possible to manufacture precise parts and reproduce complex shapes and profiles.

What machinery does Gurelan use for Zamak die casting?

Gurelan has 14 hot-chamber die casting machines, with capacities ranging from 20 to 200 tonnes.

All machines are equipped with feeders and extraction robots.

Having die casting machines with different capacities makes it possible to select the appropriate machine based on factors such as the weight and dimensions of the part or the number of cavities in the mould.

In addition to the die casting process, Gurelan has different types of machinery for carrying out subsequent operations depending on the final finish required for each part.

What role does the mould play in Zamak die casting?

The mould is a fundamental element in the die casting process, as the molten Zamak must fill its cavity to obtain the geometry of the part.

At Gurelan, mould design is carried out entirely by its technical department.

This work includes aspects such as the location of the sprue, the arrangement of the overflows and the design of the filling channels.

In addition to designing the moulds, Gurelan has the capability to manufacture them in-house.

For their development, Gurelan uses CAD-CAM methodology and tools such as SolidWorks, Solid Edge, PowerSHAPE and PowerMILL.

Zamak Die Casting at Gurelan

Gurelan specialises in the manufacture of parts using hot-chamber Zamak die casting, integrating mould design and manufacturing with the subsequent die casting process.

Its production facilities make it possible to work with parts of different dimensions and weights, selecting the machine and mould characteristics according to each project.

This process is complemented by the necessary equipment to carry out subsequent operations when required by the characteristics and final finish of the part.