From Pot Metal to Precision Zinc Alloys

Precision zinc alloys are almost universally used in the zinc die casting process. The term precision zinc alloys refers to the specific additions of metals into the molten zinc to create an alloy. For example, Zamak 3 contains roughly 4% aluminum and .01% copper, along with specific traces of other die casting metals.Although, high quality alloys has not always been the case. The phrase “pot metal” comes from the early 20th century when automotive and toy manufacturers compiled assortments of cheap metals with low melting temperatures, melted them down, and cast the mixture into parts. Pot metal has no science behind the metal mixture within the pot. This lack of consistency in metals such as zinc, lead, tin, magnesium, aluminum, iron, and cadmium can cause complications such as pitting, cracking, bending, and shattering with age. Many times common airborne acids are trapped in the pot metal mixture causing internal corrosion.Precision zinc alloys, such as Zamak, took over the zinc die casting industry after being developed in 1929, and Zamak continues to be the most used alloy in the zinc die casting industry today. The transition to high quality and science backed zinc alloys helped grow the zinc die casting industry. New developments in zinc die casting alloys are showing improvements in stress, strain, and creep resistance as well as in strength and hardness.Deco Products has been a reliable “Made in USA” zinc die casting manufacturer since 1960. Deco Products provides exceptional service and quality products for a multitude of industries. A few services Deco Products provides are custom precision engineered zinc die-casting, powder coating, assembly, CNC Machining, and DFM-Part Design. Deco has been a stable and reliable supplier to the industry and continuously strives for being the best value for its key partner/customers.

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