Casting Study: Modular Base Plate

This part is a modular base plate working in a pneumatic environment. Its function is to transport air between an air distributor and a jack. Modular base plates are made of pressure die cast Zamak 5 (ZA4UIG). The excellent fluidity of zinc alloys provides a surface condition suitable for being coated, an excellent dimensional precision, and air tightness at a pressure of 10 bars. The part is chromated after machining and provides a 96-hour resistance to salt spray.

Zamak was selected for a variety of reasons: pressure die casting to ensure consistent complex shapes and thin walls; machinability (tapping); possibility of surface treatment; and attractive manufacturing cost compared with aluminium. The repeatability of the excellent properties of Zamak 5 provides a constant quality for a part which directly or indirectly affects the reliability of controlled mechanical devices and the safety of persons and machines. Part supplied by AMI Fonderie.