Casting Study: Hausing for HSD Connector

Major Selection Criteria: Assembly, Complex Shape, Dimensional Precision, Electrical Properties, EMI/RFI Shielding, Good Finish, Integration of Multiple Functions, Mechanical Properties, Net Shape, Thin-Wall Construction
Alloy: Zamak 5 (ZL5, ZL0410, ZnAI4Cu1, alloy 5)
Application Field: Electrical/Electronics
Application Size: <5 g
Surface Finish: Other
Casting Technique: Pressure Die Casting
Source: Haveländische Zink Druckguss (HZD) Germany

ima05This HSD connector (HSD = high speed data) is a part of the control units in upper segment cars. The 4-pin connector assures large volume of data transfer as compared to the standard connector with only 1 pin. The required tolerances for this miniature part are borderline to what is technically possible with casting technology. Assembly is done by reflow soldering which implies that the entire part goes through an oven at 260°C for 210sec. Soldering metal is applied upfront and melts in this furnace to assure the connection. The casting needs to be pore free. Any remaining pores would blow up during the heating and ruin the casting. To avoid damage to the surface or the tiny positioning pins, the deburring is done cryogenically with softer polymer balls.

Reasons for choosing zinc alloy:
ZP5 was chosen over other materials for its excellent surface finish, strength, ability to cast very thin surfaces with extreme low tolerances and free of defects.