Casting Study: Waveguide Horn

Major Selection Criteria: Dimensional Precision, Electrical Properties, Integration of Multiple Functions
Alloy: Zamak 3 (ZL3, ZL0400, ZnAI4, alloy 3)
Application Field: Communications
Application Size: 1-1/2 in. x 3-1/4 in. x 9/16 in.
Surface Finish: As-Cast
Casting Technique: Pressure Die Casting
Source: Dynacast, Inc., Yorktown Hts., NY

wavegui2_photo2_caseID190The Whistler Spectrum 3SE waveguide horn is a complex Zamak 3 die casting providing detail, net shape, and thin wall construction. The current horn replaces three separate pieces utilized in earlier models. One component now performs four distinct functions: a horn antenna, a microwave cavity, RF shielding for the circuit board, and electronics mounting. A unique microwave design element is the double ridge located on the top and bottom of the horn’s interior. The ridges enable the horn to work across a broad range of microwave frequencies. The casting is produced with a nominal wall thickness of 0.040 in., with an 0.018 in. tapered edge on the mouth of the horn. The casting includes 19 through holes, two blind holes, two bosses, and two major cavities.