Dynacast brochure

SOLUTIONS MADE SOLID

ZINC SOLUTIONSSTRENGTH COMES IN MANY SIZES

Zn

Dynacast is the world’s leading precision zinc die caster. We have produced billions of zinc die cast components from one hundredth of a gram to one kilogram, using our proprietary multi-slide die casting machines and conventional hot-chamber technologies. The high strength and hardness of zinc alloy means that it is the ideal, best-cost alternative to machined, pressed, stamped and fabricated items.

razor handle

Connectors

Complex net-shaped zinc housings, with precise thin walls, give excellent electrical performance and shielding properties.

Automotive

Our automotive strength is in electronic and safety critical applications, where customers are looking for proven quality along with part-to-part consistency over high volume.

Telecommunications

The foremost supplier of zinc die castings for mobile phones, Dynacast’s proprietary multi-slide die casting process lends itself to the manufacture of these small, intricate, highly cosmetic components. Dynacast’s superior thin-wall capabilities have led to the manufacture of zinc die cast shields, flip hinges, chassis and frames for mobile phones and handheld electronics.

Computing

In computing, we are a principal supplier of small precision die cast components for personal computers and servers, as wear resistance and structural integrity are important. Some of the most complicated components we supply go into disk drives, the castability of zinc being perfect for the creation of multi-faceted, highly complex shapes.

Consumer Electronics

Dynacast’s offerings range

from digital camera mechanical components to highly complex 6-slide optical drive brackets; from highly cosmetic enclosures to heat sinks.

Dynacast Zinc Capabilities

Dynacast operates full-service die casting facilities globally. Offering aluminum and magnesium in addition to zinc, we manufacture miniature to large precision components utilizing proprietary multi-slide and conventional hot and cold chamber die casting technologies. Our knowledge, and experience combined with structured project management, supports customers from concept, through rapid prototyping, tooling and pre-production, into full-scale manufacturing.

International HeadquartersDynacast, Inc.14045 Ballantyne Corporate Place, Suite 300, Charlotte, NC 28277Phone: (+1) 704-927-2790Fax: (+1) 704-927-2791

Dynacast EuropeHüfinger Strasse 24D 78199 BräunlingenGermanyPhone: (+49) 771-9208 Fax: (+49) 771-9208-100

Dynacast Asia Pacific6 Second Chin Bee RoadJurongSingapore, 618773Phone: (+65) 6268-7644Fax: (+65) 6265-1652

Dynacast Die Casting Benefits• Over 70 years of experience

assisting OEMs designing cost-effective zinc components

• High-volume production

• Manufacture of complex net shapes

• Consistent quality over high volumes

• Tight tolerances achieved as-cast

• Value engineering achieves cost savings

• Part consolidation eliminates extra processes

• Minimal draft angles on internal features

Zinc Benefits • High strength & hardness

• Excellent electrical conductivity

• High thermal conductivity

• Low-cost raw material

• High dimensional accuracy and stability

• Excellent thin-wall capability

• Ability to cold form facilitates fastening and joining

• High-quality finishing characteristics

• Outstanding corrosion resistance

• Fully recyclable

Zamak 2 Zamak 3 Zamak 5 Zamak 7 ZA 8 ZA 27

Resistance to Hot Cracking

Pressure Tightness

Casting Ease

Part Complexity

Dimensional Accuracy

Dimensional Stability

Corrosion Resistance

Resistance to Cold Defects

Machining Ease & Quality

Polishing Ease & Quality

Electroplating Ease & Quality

Anodizing (Protection)

Chemical Coating (Protection)

Alloy Characteristics

% Zamak 2 Zamak 3 Zamak 5 Zamak 7 ZA8 ZA27

ZIN

C

Aluminum 3.5-4.3 3.5-4.3 3.5-4.3 3.5-4.3 8.0-8.8 25.0-28.0

Copper 2.5-3.0 2.5 max 0.75-1.25 0.25 max 0.8-1.3 2.0-2.5

Magnesium 0.02-0.05 0.02-0.05 0.03-0.08 0.005-0.02 0.015-0.03 0.01-0.02

Iron (max) 0.1 0.1 0.1 0.075 0.075 0.075

Lead (max) 0.005 0.005 0.005 0.003 0.006 0.006

Cadmium (max) 0.004 0.004 0.004 0.002 0.006 0.006

Tin (max) 0.003 0.003 0.003 0.001 0.003 0.003

Nickel — — — 0.005-0.02 — —

Others — — — — — —

Zinc remainder remainder remainder remainder remainder remainder

Alloy Composition

steering column lock housing

key lock

microwave guide

optical slider base

PERFORMANCE RATING: BEST LEAST


ADVANCED ENGINEERINGTHINK FORWARD

Dynacast is at the forefront of the die casting industry in engineering and process technology. Integrating Computer Aided Engineering into our structured project management methods, we support customers from concept, through prototyping, tooling and pre-production stages, into full-scale manufacturing. Right-the-first-time components, produced through advanced quality planning, reduce overall time to market and achieve major cost savings for our customers.

Advanced 3-D Modeling

At the core of the systems used by Dynacast is the ProEngineer™ suite of advanced 3-D design and modeling software, which is standardized throughout the group for the purpose of designing and manufacturing components, castings, and tools. Our early involvement with customers’ design engineers ensures that component designs are optimized for the

die casting process.

Virtual Prototyping & Simulation

Using virtual prototyping and simulation techniques, such as Finite Element Analysis, engineers can examine how a component will operate in service and investigate different design possibilities without the need for physical parts.

From the data generated, process simulation techniques can then predict characteristics of cavity fill and casting solidification with a high degree of accuracy. This highlights tool and component design improvements before toolmanufacture, helping eliminate die casting defects that may prove critical to the functionof the component.

DIE-FILLING SIMULATION ensures right-the-first-time tool manufacture.

PRO ENGINEER™ 3-D CAD VIEW

of proprietary Dynacast multi-slide tool.




Dynacast Technology

• Reduces the need for physical prototypes in some cases

• Latest processes in rapid tooling and prototyping technology, such as stereolithography, 3-D printing and highspeed machining

• Prototype single cavity tools with true die casting mechanical properties in 2-4 weeks

• Economical direct high-speed machining of tool cavities

• Direct machining of electrodes and cavities from the tooling engineer’s design data, using ProManufacture™, fully integrated with ProEngineer™

• Time delays are minimized by using concurrent design activities with customers, advanced modeling and Dynacast’s Best Practice tool design techniques

• Local access to global engineering expertise and tooling information, facilitates collaborative product development

• Dynacast also has many experts in the fields of metallurgy and process engineering providing expertise in:

Die materials

Casting materials

Process monitoring & improvement

Finishing

Failure & defect analysis

• Consistently extending the bounds of die casting technology, we develop our knowledge for the future by close liaison with suppliers’ research facilities, industry associations and our own R&D activities

INJECTION METAL ASSEMBLYUsing sophisticated zinc alloy die

casting technology as a joining method allows us to find cost

effective solutions for your most complex assembly problems.

PRECISION CAST Complex geometries are

achieved with Dynacast’s advanced engineering techniques.

ALUMINUM SOLUTIONSTAKES THE HEAT

Ideal for harsh environments, aluminum die castings are lightweight, yet withstand the highest operating temperatures of all the die cast alloys. Its strength, rigidity, corrosive resistance and heat dissipating properties offer significant advantages to mechanical designers. Fully recyclable aluminum die cast alloys are secondary alloys 100% derived from primary aluminum scrap, an environmental advantage over primary aluminum alloys for machining, which have to be mined and extracted from ore.

Al

seat belt retractor spool


Telecommunications & ComputingIn telecoms and computing they are used in a broad range of networking and infrastructure equipment, most importantly RF filter boxes and various housings into which heat sinks are often designed as an integral component.

Handheld DevicesIn handheld devices, aluminum die cast shields and housings give EMI shielding, rigidity and durability with minimal additional weight. This is most important in electronic equipment where emission and interference suppression requirements are high.

AutomotiveAluminum die castings in vehicles significantly contribute to the weight-saving requirements needed to improve fuel economy.

Our strength in automotive is in electronic applications, such as shields for telematic equipment and housings for sensors, where customers are looking for proven quality along with part-to-part consistency over high volume.

In safety-critical occupant restraint systems, Dynacast is a leading supplier of airbag housings and retractor spools.

ConnectorsDynacast aluminum die castings are fundamental to the manufacture of heavy-duty electronic connectors, where complex housings give excellent electrical performance and shielding properties, especially in high-temperature environments.

Dynacast Aluminum CapabilitiesDynacast operates aluminum die casting facilities globally. A full-service die caster offering zinc and magnesium in addition to aluminum, Dynacast manufactures precision components utilizing proprietarymulti-slide and conventional hot and cold chamber die casting technologies. Dynacast’s knowledge, combined with structured project management methods, supports customers from concept, through rapid prototyping, tooling andpre-production stages, as well as full-scale manufacturing.

Aluminum Benefits• Withstands high operating

temperature

• Outstanding corrosion resistance

• Lightweight

• Very good strength and hardness

• Good stiffness and strength to weight ratio

• Excellent EMI shielding properties

• Excellent thermal conductivity

• Good finishing characteristics


• Aluminum die cast alloys are secondary alloys 100% derived from primary aluminum scrap


assisting OEMs designing cost effective components

• High-volume production




• Part consolidation eliminates operations

• Proprietary thin-wall aluminum technology

• Complex CNC machining of aluminum die castings available at all aluminum facilities

Alloy Composition

% A380 383 413

ALU

MIN

UM

Beryllium — — —

Copper 3.0-4.0 2.0-3.0 1.0 (max)

Iron (max) 1.3 1.3 2.0

Magnesium 0.1 (max) 0.1 (max) 0.1

Manganese 0.5 (max) 0.5 (max) .35

Phosphorus — — —

Silicon 7.5-9.5 9.5-11.5 11.0-13.0

Zinc (max) 3.0 3.0 0.5

Nickel (max) 0.5 0.3 0.5

Tin 0.35 (max) 0.15 (max) 0.15

Titanium — — —

Others 0.5 (total) 0.5 (total) 0.25 (total)

Aluminum remainder remainder remainder

Alloy CharacteristicsA380 383 413

Pressure Tightness




Anodizing (Appearance)

Anodizing (Protection) — —

Die Filling Capacity

Anti-Soldering to the Die


Polishing Ease and Quality

Oxide Protective Coating

Strength at Elevated Temp.

heat sink

airbag housing




BEST LEASTPERFORMANCE RATING:

tv lamp bracket

thin-walled component


AUTOMOTIVE SOLUTIONSEFFICIENCY IN MOTION

We are a leading supplier to the automotive industry of components ranging from less than one hundredth of a gram to one kilogram, in zinc, aluminum and magnesium. Supplying customers globally, Dynacast is accustomed to working to the just-in-time supply requirements of the automotive OEMs and Tier-1 manufacturers. Manufacturing billions of components each year, we consistently meet the industry’s most stringent tolerances.

seat belt retractor spool

The World’s Leading Automotive Die Caster.

The majority of vehicles within North America, Europe and Asia contain die castingsmanufactured by Dynacast. Dynacast’s proprietary multi-slide die casting process, combined with conventional hot and cold chamber die casting, is highly suited for the manufacture of complex components. Utilizing these technologies, Dynacast hasbecome the leading supplier of precision zinc, aluminum and magnesium parts to the automotive industry.

ApplicationsDynacast’s experience is unrivaled in the design, development and manufacture of precision die cast solutions for a wide range of vehicle applications:

• Shielding telematic and electronic equipment

• Sensor and airbag housings

• Zero defect seat belt retractor spools

• Precision components for instrumentation switches

• Intricate lock barrels

• Lightweight components for improved vehicle fuel economy




Die Casting Benefits• Over 70 years of experience

assisting OEMs designing cost- effective components

• Magnesium and aluminum components help reduce vehicle weight

• Precisely cast, thin-walled housings provide shielding for an ever-increasing number of electronic sensors

• Can incorporate features for positioning electronic componentry and heatsinks within a net-shape design

• Vital shielding for telematics, which integrate telecommunications, navigation, and entertainment features within the vehicles’ systems

• Connector housings for vehicle electronic and electrical systems manufactured in all shapes and sizes in zinc, aluminum and magnesium

• Fully recyclable die castings help achieve stricter product recycling requirements

• Die castings accept a wide variety of finishes from high-specification plating to cosmetic finishes for the demanding customer

Dynacast Die Casting CapabilitiesDynacast operates zinc, aluminum and magnesium die casting facilities globally, manufacturing miniature to large precision components utilizing proprietary multi-slide and conventional hot and cold chamberdie casting technologies. Dynacast’sknowledge, combined with structured project management methods, supports customers from concept, through rapid prototyping, tooling and pre-production stages, as well as full-scale manufacturing.

steering column ignition lock housings

air bag housing

electronic rain sensor housing

engine control module

headlamp adjustor


CONNECTOR SOLUTIONSWE’RE ALL CONNECTED

Constant innovation in connector technology means Dynacast engineers, around the world, play a defining role in setting the international standards in die cast solutions for connection systems of the future. Time-to-market and guaranteed high-volume supply of quality components are critical, while consolidation of the connector industry increasingly demands we deliver concept to production anywhere in the world.

Product ApplicationDynacast’s extensive global experience encompasses die cast connector components in zinc, aluminum and magnesium for these principal industries:• communications• computing• consumer electronics• automotive electronics

Dynacast is also fully involved in the booming connector markets for high-speed applications, wireless devices, wireless infrastructure equipment and fiber optics. Participating for over two decades in the fiber optic sector alone, we routinely apply this expertise across other connector market sectors, to achieve the optimum product application.

Economic PrecisionFor connector components traditionally manufactured by machining, Dynacast offers a more economically precise solution, when designed as, or converted to a die casting. Meeting tight tolerances consistently over high volume production, our unique high-speed multi-slide die casting process lends itself to the manufacture of intricate three dimensional connector housings and assemblies, in both zinc and magnesium.

Dynacast utilizes its broad range of conventional machines to die cast larger complex connector components in zinc and aluminum.

large complex cylindrical connector housing





assisting OEMs designing cost-effective components

• Cast housings are extremely durable

• Fully recyclable for achieving stricter product legislation

• Wide variety of finishes from high-specification plating to cosmetic finishes for the demanding customer

• Cost-effective, high-volume production







Dynacast Die Casting CapabilitiesDynacast operates zinc, aluminum and magnesium die casting facilities globally, manufacturing miniature to large precision components utilizing proprietary multi-slide and conventional hot and cold chamber die casting technologies. Dynacast’s knowledge, combined with structured project management methods, supports customers from concept, through rapid prototyping, tooling and pre-production stages, as well as full-scale manufacturing.

shielded ethernet connector

fiber optic transceiver body and cover

electrical connector

telematic antenna base


CONSUMER ELECTRONICSSMALL AND GETTING SMALLER

Think of any consumer electronics product and it will probably contain die castings. With goals of zero defect quality, Dynacast is the preferred partner of many of the world’s leading consumer electronic manufacturers, supplying superior precision die castings, that have part-to-part consistency over high volume. With innovations occurring in all sectors of the industry, time-to-market and providing cost-effective solutions are critical. Dynacast engineers offer ground-breaking solutions to these challenges.

Wide Range of Product Applications Consumer electronics embraces a wide range of products from HD DVD to digital cameras, high-tech domestic equipment to mp3 players. Having built long-term relationships with major manufacturers, we continue to pioneer leading-edge die castings for their latest innovations in zinc, thin-wall aluminum and magnesium. Dynacast’s proprietary multi-slide die casting process lends itself to the manufacture of complex components.

AccuracyOur ability to design with minimal draft means that a part can have internal features cast into it without the need for additional operations, significantly increasing accuracy and saving on costly secondary

processes. Optical disk drives used in the rapidly growing market for Blu-Ray players are amongst the most complicated components manufactured by Dynacast. The castability of zinc and magnesium is perfect for the creation of multi-faceted highly complex shapes.

Handheld DevicesMagnesium’s greatest potential lies in handheld devices, where emission and interference suppression requirements are high. Precisely cast thin-walled parts provide RFI EMI shielding and can incorporate features for positioning electronic componentry, adding minimal weight with maximum rigidity.

mp3 player chassis







• Integration of heat sinks within product design











camera lens holder

mobile back plate

hdtv lamp bracket

mp3 player housing

mobile phone hinge & decorative parts


DIGITAL SOLUTIONSMORE THAN 1s & 0s

With computer users demanding increasing portability and storage capacity, computer designs continue to be dynamic. Time-to-market is critical, along with guaranteed high-volume supply of quality components. Dynacast offers innovative die cast solutions for all types of computer applications, and is at the leading edge of designs for the new breed of computers with integrated communication functions.

heat sink

Product Applications Dynacast has significant global experience in the manufacture of parts for:• laptop computers• computer servers• peripherals• network & infrastructure

equipmentDynacast’s proprietary multi-slide die casting process lends itself to the manufacture of complex components used in portable computers, with zinc offering the right material properties for mostrequirements.

Handheld DevicesMagnesium’s greatest potential lies in handheld devices, where emission and interference suppression requirements are high. Precisely cast thin-walled parts provide EMI shielding and can incorporate features

for positioning electronic componentry, adding minimal weight with maximum rigidity.

Light & DurableMinimal additional weightfrom shields and frames gives maximum benefits in rigidity to ever-smaller and lighter devices. Die cast housings are extremely durable and can integrate heat sinks within their product design. Weight-saving requirements combined with the need for heat dissipation have made us the source of computer HDD server rails, cast with high precision in aluminum.

An important application in computing is connector housings, which Dynacastmanufactures in all shapes and sizes — in zinc, aluminum and magnesium.

Optical disk drives are among the most complicated components manufactured byDynacast. The castability of zinc and magnesium is perfect for the creation of multi-faceted highly complex shapes.











• Proprietary thin-wall aluminum technology particularly helpful in computing applications








network storage device rail

lap top hinges

shielded ethernet connector

optical slider base


HARDWARE SOLUTIONSSUPPLY MEETS THE MOST DEMANDING INDUSTRY

We appreciate that hardware is a demanding industry, requiring numerous solutions with competitive pricing; every job presents a unique challenge. Complex geometries, rapid turn around, defect free production, most often all of the above. The more demanding a project, the more unique the specifications, the more you need Dynacast as your die casting partner. We are the world’s largest die-caster, offering global expertise and efficiencies of scale that allow us to offer you the lowest total acquisition cost. Now what else could you demand?

Custom Designed SolutionsWith more than 20 locations around the world, Dynacast is the preferred supplier to the world’s leading hardware markets. Offering the tightest tolerances, widest range of geometries, and aesthetic options, so you can be confident we will customize the right solution for you.

A Variety of ApplicationsHardware is a diverse industry. With applications ranging from window locks to power tool motors, we expect customers to demand quality product turned around quickly. Regardless of the component’s complexity or volume produced, all our die castings receive our highest level of expertise and precision.

Every customer receives a highly repeatable, customized process that yields quality components that are consistent to your specifications.

Optimized Supply Chain

Our industry leading technology in zinc, aluminum, magnesium die casting, and proprietary multi-slide and conventional technology give us the depth of experience and equipment precise enough to meet the demands of the hardware market. Supported by a network of certified finishing suppliers, Dynacast delivers your product finished and ready to go directly to your assembly line or direct to your customer.rotating screwdriver base




Dynacast Die Casting Benefits

• Over 70 years of experience assisting Hardware OEMs designing cost effective components

• High efficiency Dynacast processes yield supply cost lower than many customer’s in house manufacturing cost

• Fully recyclable material helps satisfy increasingly strict product legislation

• Wide variety of finishes

• Cost effective high volume production




• Value engineering


• Dynacast Industrial Products Division offers a variety of commercial fasteners in stock at www.dynacast-IP.com

Dynacast Die Casting Capabilities

Dynacast operates zinc, aluminum and magnesium die casting facilities globally, manufacturing miniature to large precision components utilizing proprietary multi-slide and conventional hot and cold chamber die casting technologies. Dynacast’s knowledge, combined with structured project management methods, supports customers from concept, through rapid prototyping, tooling and pre-production stages, as well as full-scale manufacturing.

key lock assembly

wall hooks

no drip couplings


MAGNESIUM SOLUTIONSLIGHT AS PLASTIC

Magnesium is the ideal material for applications where weightsaving is a priority, as it has the lowest density of all structural metals. Almost as light in weight as plastic, magnesium has the advantage of greater strength and rigidity, along with inherent EMI shielding and full recyclability.

Mg

mp3 player chassis

Handheld ElectronicsMagnesium’s greatest potential lies in all types of handheld electronic devices, from mobile phones to mp3 players, cameras to smart phones, especially with the emission and interference suppression requirements of electronic devices.

Weight AdvantagesMinimizing weight in handheld devices is a key requirement, and magnesium lends itself to the manufacture of shields and frames. Precisely cast thin-walled parts provide EMI shielding, and can integratefeatures for positioning electronic componentry. Minimal additional weight gives maximum benefits in rigidity to ever-smaller electronic devices.

HousingsFor housings, magnesium is extremely durable and can integrate heat sinks within their product design. Ideal for decorative components, magnesium will accept a wide range of fashionable finishes with the added benefit of the quality feel of metal.

ComputingIn computing, magnesium’s low inertia due to its light weight and excellent dampening characteristics, gives it a distinct advantage over other materials in the manufacture of disk drives.

AutomotiveFor automotive engineers, magnesium significantly contributes to weight-saving requirements in their quest to improve vehicle fuel economy.

RecyclabilityImportant to all industries, magnesium’s recyclability helps manufacturers meet increasing product recycling legislation.




Dynacast Magnesium CapabilitiesDynacast operates magnesium die casting facilities globally. A full-service die caster offering zinc and aluminum in addition to magnesium, Dynacast manufactures miniature to large precision components utilizing proprietary multi-slide and conventional hot and cold chamber die casting technologies. Dynacast’s knowledge, combined with structured project management methods, supports customers from concept, through rapid prototyping, tooling and pre-production stages, as well as full-scale manufacturing.

Magnesium Benefits• The lightest of all structural metals

• Excellent stiffness & strength-to-weight ratio

• Outstanding EMI shielding properties

• High electrical and thermal conductivity

• Withstands high operating temperatures

• Cost effective versus many engineered thermoplastic materials

• High dimensional accuracy and stability

• Exceptional thin-wall capability• Good environmental corrosion

resistance• Good finishing characteristics• Fully recyclable


assisting OEMs designing cost effective components

• High volume production







% AZ91D AM60Bt

MA

GN

ESI

UM

Aluminum 8.3-9.7 5.5-6.5

Manganese 0.15-0.5 0.24-0.6

Zinc 0.35-1.0 0.22 (max)

Silicon (max) 0.1 0.1

Copper (max) 0.03 0.01

Nickel (max) 0.002 0.002

Iron (max) 0.005 0.005

Other Metallic (max) 0.02 0.02

Magnesium remainder remainder

Alloy Composition

AZ91D AM60Bt

Resistance to Cold Defect

Pressure Tightness




Surface Treatment

Die Filling Capacity

Anti-Soldering to the Die


Polishing Ease and Quality

Oxide Protective Coating

Strength at Elevated Temp.

Alloy Characteristics electronic rain sensor housing

mobile phone back plate

soccer shoe cleats

BEST LEASTPERFORMANCE RATING:

Al Mg Zn Materials CoMparison

FroM aluMinuM to zinC

Dynacast global die casting facilities manufacture miniature to large precision components in a broad range of zinc, aluminum and magnesium alloys, utilizing proprietary multi-slide and conventional hot and cold chamber die casting technologies.

Each of these alloys has unique mechanical and physical characteristics to match your specific application. Through value engineering, Dynacast engineers develop component solutions that add value and product differential. Dynacast knowledge and project management, supports customers from concept, through rapid prototyping, tooling and pre-production stages, as well as into full-scale manufacturing.

solutions Made solid

% a380 383 413

alu

Min

uM

Beryllium — — —

Copper 3.0-4.0 2.0-3.0 1.0 (max)

iron (max) 1.3 1.3 2.0

Magnesium 0.1 (max) 0.1 (max) 0.1

Manganese 0.5 (max) 0.5 (max) .35

phosphorus — — —

silicon 7.5-9.5 9.5-11.5 11.0-13.0

zinc (max) 3.0 3.0 0.5

nickel (max) 0.5 0.3 0.5

tin 0.35 (max) 0.15 (max) 0.15

titanium — — —

others 0.5 (total) 0.5 (total) 0.25 (total)

aluminum remainder remainder remainder

% az91d aM60Bt

Ma

gn

esi

uM

aluminum 8.3-9.7 5.5-6.5

Manganese 0.15-0.5 0.24-0.6

zinc 0.35-1.0 0.22 (max)

silicon (max) 0.1 0.1

Copper (max) 0.03 0.01

nickel (max) 0.002 0.002

iron (max) 0.005 0.005

other Metallic 0.02 0.02

Magnesium remainder remainder

% zamak 2 zamak 3 zamak 5 zamak 7 za8 za27 aCuzinc5 Beric

zin

C

aluminum 3.5-4.3 3.5-4.3 3.5-4.3 3.5-4.3 8.0-8.8 25.0-28.0 2.8-3.3 3.0-4.0

Copper 2.5-3.0 2.5 max 0.75-1.25 0.25 max 0.8-1.3 2.0-2.5 5.0-6.0 3.0-4.0

Magnesium 0.02-0.05 0.02-0.05 0.03-0.08 0.005-0.02 0.015-0.03 0.01-0.02 0.025-0.05 .04

iron (max) 0.1 0.1 0.1 0.075 0.075 0.075 0.075 —

lead (max) 0.005 0.005 0.005 0.003 0.006 0.006 0.005 —

Cadmium (max) 0.004 0.004 0.004 0.002 0.006 0.006 0.004 —

tin (max) 0.003 0.003 0.003 0.001 0.003 0.003 0.003 —

nickel — — — 0.005-0.02 — — — —

others — — — — — — — .04Be .1Ti

zinc remainder remainder remainder remainder remainder remainder remainder remainder

alloy CoMpositions

international Headquarters

Dynacast, Inc.14045 Ballantyne Corporate Place, Suite 300, Charlotte NC 28277Phone: (+1) 704-927-2790Fax: (+1) 704-927-2791

dynacast europe

Hüfinger Strasse 24D 78199 BräunlingenGermanyPhone: (+49) 771-9208 Fax: (+49) 771-9208-100

dynacast asia-pacific

6 Second Chin Bee RoadJurongSingapore, 618773Phone: (+65) 6268-7644Fax: (+65) 6265-1652

ultimate tensile strengthyield strength (0.2% offset) impact strength shear strength Hardness elongation

MPa PSI x 10^3 MPa PSI x 10^3 J ft lb MPa PSI x 10^3 Brinell % in 50mm

zinc

Zamak 2* 359 52 283 41 47 35 317 46 100 7

Zamak 3* 283 41 221 32 58 43 214 31 82 10

Zamak 5* 328 48 228 33 65 48 262 38 91 7

Zamak 7* 283 41 221 32 58 43 214 31 80 13

ZA 8* 374 54 290 42 42 31 275 40 103 6-10

ZA 27* 425 61 376 55 12.8 9.4 325 47 119 1-3

ACuZinc5*** 407 59 338 49 — — 280 40 115 5

MagnesiumAZ91D 230 34 160 23 3.0 2.0 140 20 63 3

AM60B t 220 32 130 19 — — — — 62 8

aluminum

A380** 325 47 160 23 4 3 185 27 80 3.5

383** 310 45 150 22 4 3 190 28 75 3.5

413** 295 43 145 21 — — 170 25 80 2.5

BrassC38500 430-530 62-77 228 33 17 12 — — 143 15-25

C38800 420-460 61-67 228 33 16 12 — — 133 20-25

steel SAE1008a 290-360 42-52 140-275 20-40 — — — — 125 30

MeCHaniCal properties

density Melting range thermal ConductivityCoefficient of

thermal expansionelectrical

Conductivity

g/cm3 lb/in3 °C °F W/m K Btu-ft/h-ft2°F μm/m°K x10-6 °F-1 %IACS

zinc

Zamak 2* 6.60 0.240 379-390 715-734 104.7 60.5 27.7 15.4 25.0

Zamak 3* 6.60 0.240 381-387 718-728 113.0 65.3 27.4 15.2 27.0

Zamak 5* 6.60 0.240 380-386 717-727 108.9 62.9 27.4 15.2 26.0

Zamak 7* 6.60 0.240 381-387 718-728 113.0 65.3 27.4 15.2 27.0

ZA 8* 6.30 0.227 375-404 707-759 114.7 66.3 23.3 12.9 27.7

ZA 27* 5.00 0.181 375-487 708-903 125.5 72.5 26.0 14.4 29.7

ACuZinc5*** 6.85 0.247 402-502 755-936 106.0 61.2 24.1 13.3 26.9

MagnesiumAZ91D 1.81 0.066 470-595 875-1105 72.3 41.8 25.2 14.0 12.2 (NA)

AM60B t 1.79 0.065 540-615 1005-1140 61.0 36.0 25.6 14.2 12.4 (NA)

aluminum

A380** 2.71 0.098 538-593 1000-1100 96.0 55.6 21.2 11.8 27.0

383** 2.74 0.099 516-582 960-1080 96.0 55.6 21.1 11.7 23.0

413** 2.66 0.096 574-582 1065-1080 121.0 70.1 20.4 11.3 31.0

BrassC38500 8.4 0.30 880-900 1616-1652 113.0 65.3 26.0 14.4 26.0

C38800 8.4 0.30 900-920 1652-1688 109.0 62.9 21.0 11.7 25.0

steel SAE1008a 7.8 0.28 1426 2600 60.0 34.7 — — 12.0

pHysiCal properties

Typical die casting mechanical & physical properties: * per ASTM B86-06 ** per ASTM B85/B 85M-08 *** per SAE 930788 t per ASTM B94-94 ª per ASTM A1008/A 1008M -08a

www.dynaCast.CoM

us designation

european designation

us standard

european standard

zinc

Zamak 2 ZP2 ASTM B86 EN12844



Zamak 7 — ASTM B86 —

ZA8 ZP8 ASTM B791 EN12844

ZA27 ZP27 ASTM B791 EN12844

ACuZinc5 — SAE 930788 —

aluminum

A380 46500 ASTM B85 EN1706

383 46100 ASTM B85 EN1706

413 46700 ASTM B85 EN1706

MagnesiumAZ91D MC21121 ASTM B94 EN1753

AM60A MC21230 ASTM B94 EN1753

designations & standards


LOUD & CLEAR

Telecommunications engineers face the challenge of designing in a highly dynamic technological environment. Constant innovation means time-to-market is critical, along with guaranteed high-volume supply of quality components. Dynacast offers pioneering die cast solutions for all types of telecommunications applications, and is at the leading edge of designs for the new breed of mobile communication equipment with integrated computing functions, including Internet connectivity.

TELECOMMUNICATIONS SOLUTIONS

Mobile Applications Dynacast has significant global experience in the manufacture of parts for mobile phones, network equipment, and connectors. Designers and consumers love having the look and feel of metal in their devices. Dynacast’s proprietary multi-slide die casting process lends itself to the manufacture of small complex mobile phone components. The castability of zinc is perfect for the creation of their complex shapes.

Handheld DevicesMagnesium’s greatest potential lies in handheld devices, especially those packed with electronic features, where emission and interference suppression requirements are high. Precisely cast thin-walled parts provide EMI shielding and can incorporate features for positioning electronic componentry.

NetworkingDie castings are used in a broad range of networking equipment from aluminum cast RF filter boxes in base stations to high-precision die cast zinc pins in switching systems; from shielding boxes for microwaves to a wide variety of heat sinks. One of the most important applications is connector housings, which Dynacast manufactures in all shapes and sizes, in zinc, thin-walled aluminum and magnesium.

Light & DurableMinimal additional weightfrom shields and frames gives maximum benefits in rigidity to ever-smaller and lighter devices. Die cast housings are extremely durable and can integrate heat sinks within their product design.




Dynacast Die Casting Benefits• Manufacture of complex net shapes




• Over 70 years of experience assisting OEMs designing cost effective components








• Proprietary thin-wall aluminum technology for telecommunication devices


mobile phone back plate

fiber optic transceiver body and cover

mobile phone hinges & decorative parts

telematic antenna base


VALUE COMES FIRST

Die casting is the engineered alternative to pressing, stamping, turning, machining, fabricating, assembly or molding. It can have significant advantages over other manufacturing processes, often leading to major cost savings, not only in the component price itself but also in overall cost of production, including assembly, secondary operations and inventory. Dynacast is the expert in the design of die castings, utilizing Value Analysis, Value Engineering, and Design For Manufacturing techniques to optimize cost savings.

VALUE ANALYSIS & ENGINEERING

conversion of six piece assembly to one piece die cast telecommunications component

Die Casting Benefits

• Cost effective, high volume production with part-to-part consistency


• Manufacture of complex net shapes, including external threads and complex internal features with minimal draft angles, thereby minimizing secondary operations

• Multiple parts can be combined into a single component eliminating assembly operations and lowering labor costs, with the added benefits of simplified stock control & greater component consistency

• Allows variable wall thicknesses, casting of features for component positioning and ribs for heat dissipation

• Achieves fewest steps from raw material to finished parts

• Fast production cycle times

• Reduction in material scrap

• Long tool life, especially for zinc and magnesium

Alloy Benefits

• Withstands high operating temperatures

• Good corrosion resistance

• Aluminum and magnesium offer lightweight options with excellent stiffness-to-strength weight ratio

• High strength and hardness

• Outstanding EMI/RFI shielding properties

• High thermal conductivity

• High electrical conductivity

• Zinc and magnesium have high dimensional accuracy and stability

• Zinc and magnesium have excellent thin-wall capability

• Proprietary thin wall aluminum technology expands component conversion opportunities for aluminum

• Good finishing characteristics





Value Analysis / Value Engineering SeminarMany of our customers have made genuine cost savings and improvement of their bottom line through Dynacast’s Value Analysis/ Value Engineering Seminar which is designed to help you save money and optimize your manufacturing process. These seminars review organized studies of component function with a search for improvements at lower cost and higher quality, proactively contributing to continuous improvement. Dynacast VA/VE seminars are free of charge. We provide the expertise, presentation and samples–all you provide is the venue and the people to train.

Learn die casting design methods to:

• Convert components produced by more costly processes to net-shape die cast components

• Consolidate multiple parts into a single component

• Minimize secondary / assembly operations

• Take full advantage of die cast process advantages

Gain experience in:

• Die casting technology, both multi-slide and conventional

• Choosing the optimum die cast process and material for an application

• The mechanical and physical properties of die casting alloys

• The Dynacast Technology Road Map an advanced look at the new processes we are developing

Who should attend:

• Product designers and engineers• Material specifiers and

manufacturing engineers• Managers of design, product

engineering and purchasing• Value analysis engineers

VALUE ENGINEERING IN PRACTICE

ApplicationNo drip fuel connectors:

Conversion to zinc die casting opened up a new market for an industry leading fluid connector company’s line of plastic no drip connectors. Plastics are vulnerable to corrosive fluids, but die cast no drip quick coupling connectors are suitable for use with gasoline.

ApplicationHinged flapper: rejects “bad coins” in slot machines and coin sorters.

Originally conventional die casting, the component was redesigned with weight savers and the multi-slide tool allowed the customer to add cast pivot bosses which resulted in a better fit and improved quality due to part to part uniformity of a single cavity tool.

CONVERSION FROM CONVENTIONAL TO MULTI-SLIDE DIE CASTING:The right metal with the right process.

ApplicationPivot Block Clamp: part of a mechanism used in slot machines and coin sorters.

The component acts as a specialized hinge aligning the cover and shaft into the perfect position. One of 50 different industries we serve.

CONVERSION FROM ALUMINUM MACHINED TO ZINC DIE CAST:Eliminated machining operations, improved product performance & reduced cost.

CONVERSION FROM PLASTIC TO ZINC DIE CAST:Higher strength, better resistance to corrosive fluids, & new markets opened.