FAQ

What is a trim die?

Trim die is a tool for trimming gating, overflows and flash from a casting. It involves the use of a hydraulic/electric trim press. Trimmed material is re-processed.

What quality steel should I use?

Die Materials: H-13 used for long run die castings.

P-20 used for moderate runs.

Mild steel used for short runs.

Why come to Joyner’s?

For 50 years Joyner’s has been casting and finishing zinc die castings. We are unique in our ability to produce a ‘hardware’ finish casting, then apply a beautiful glistening chrome or gold plated finish for years of durability and beauty.

We add value by employing an in-process quality checks for visual defects. Defects which are not readily visible on a raw casting are sample buffed twice per hour to verify acceptable, consistent surface quality.

Of course, Joyner’s dedicated staff can supply many other finishes to satisfy the most discriminating customer. All casting and finishing is done under one roof, eliminating transportation costs, expediting headaches and disputes over responsibility for quality issues.

Is zinc hazardous?

Is zinc stronger than plastic?

Yes

Do we have vacuum?

Yes. It is effectively used to remove surface porosity from castings, simplifying finishing.

Does thin wall casting have sufficient strength?

Yes, depending on design, reinforcing ribs etc.

Is zinc recyclable?

Yes

Which zinc alloys can we cast and plate?

#2, 3, 5, 7, ZA-8, and thin wall.

How does cast zinc compare with cast aluminum?

Zinc alloys #2, #3, #5, #7 and ZA-8 offer higher tensile strength than most aluminum and magnesium alloys. They also have higher yield strengths, greater impact resistance, higher Brinell hardness and better ductility. Zinc alloys also allow higher die casting cycle speeds compared to aluminum and magnesium, more complex shapes, thinner wall sections, smoother surface finishes and higher standards of dimensional accuracy.

How do zinc alloys compare with plastic?

Zinc alloys are generally stronger and more rigid, compared to plastic.

How are zinc castings finished?

They can be easily plated, painted, chromated or powder coated. Joyner’s insistence on providing dense, porosity free castings minimizes finishing problems due to casting defects.

What is ZAMAK?

Zamak: acronym for zinc, aluminum, magnesium and copper, found in #2, 3, 5, 7 alloys.

Zamak #3 alloy is the most popular alloy in the United States due to mechanical properties, castability, high quality surface finish, and ease of plating.

Higher aluminum content in ZA alloys (ZA-8, Z-12, Z-27, where the number designates percentage of aluminum in the alloys) provides higher strength, superior wear resistance and creep resistance, and lower densities. However plating process is slightly more complicated and expensive. ZA-8 alloy can be cast in hot chamber machine and plated like Zamak alloys.

What are unit dies?

Unit Dies involve the use of a standard die holder frame owned by die caster. The customer owns the insert with cavity(s). These results in lower tooling costs to the customer and faster die changes by die caster.

What surface finishes does Joyner’s offer?

Surface textures:

Various textures can be applied to the die, allowing for variety of final finish, and minimizing finishing cast.

Surface finishes:

Bright, mirror, buffed – highly reflective casting finish with any plated deposit.

Brushed or satin – fine, lined finish applied to casting prior to plating, occasionally after plating.

Matte finish – applied to tool surface or as secondary operation for non reflective surface, or with special plating solutions.

What is E-coat?

E-coat is a durable electrophoretic process in clear or colors. Clear E-coat is used to protect brass, bronze, gold plates from wear and oxidation. Color used for inexpensive color coding with a durable finish.

What is Prototype casting?

Prototype Casting is the use of plaster, sand or rubber molds to obtain fast, inexpensive tooling. This is a great process for initial design review or short-run requirements.