Casting Study: Cover Plate e-drive

Major Selection Criteria: Complex Shape, Dimensional Precision, Mechanical Properties, Net Shape, Thermal Conductivity
Alloy: Zamak 5 (ZL5, ZL0410, ZnAI4Cu1, alloy 5)
Application Field: Electrical/Electronics
Application Size: >250 g
Surface Finish: As-Cast
Casting Technique: Pressure Die Casting
Source: DYNACAST Osterreich GmbH

ima01The part is used in a drive system as a special shield to guarantee a good air ventilation and with that a perfect cooling of the system.

Technical details about the drive system:
-Technology: Integrated drive system motor
-Power Range: 60 W up to 150 kW
-Speed Range: Up to 40 000 RPM
-Voltage Range:12 up to 450 VDC
-Frame Size: Custom
-Cooling Types: Air cooled, medium cooled

Reasons for choosing zinc alloy:

  • Complex tool design
  • Cast to size
  • Saving of expensive machining
  • Excellent Process Control
  • Dimensional requirements e.g.
    – flatness 0,2
    – concentricity 0,1
    – diameter of 40 M8

Applications: Tooling appliances, fans, pumps, vacuum pumps, textile machines, printing apparatuses, lifting and handling devices, conveyer belts and within mobile applications, axillary and traction drives such as automotive electric bikes and electric fun cars for instance.

  • Part weight: 687g
  • Dimension: 150 x 137 x 36 mm
  • Cavity: 1
  • Casting: FRECH 125to plus trimming