Dirak Lock System Accessories and Lock Cylinders Metal Casting Supply

Alloy Selection for Locking Mechanisms

Lock components such as cylinders, cams, and rotary latch covers were cast using Zamak 5 and A380 aluminum alloys, chosen based on required strength, machinability, and surface finishing.

Material Performance Comparison

See our zinc alloy die casting services and aluminum HPDC capabilities to understand alloy suitability for enclosure hardware.

Mold Design for Cylindrical Components

Cylinder and core molds require tight roundness tolerances, straight bores, and parting line management. Precision slide cores and micro-venting were used to ensure clean profiles and sharp edges on internal drive features.

Mold specifications:

• Mold steel: H13, nitrided, Ra ≤ 0.8 µm

• Ejection system: stripper plates and push pins

• Roundness control: ≤0.02 mm deviation

• Mold cycle time: 35–45 seconds

Review our tool and die making capabilities for precision-cylindrical locking components.

Die Casting and Dimensional Stability

Cold chamber aluminum and hot chamber zinc die casting machines were used depending on part complexity and batch size. Servo-controlled injection and vacuum venting reduced turbulence and porosity.

Casting parameters:

• Wall thickness: 1.5–3.0 mm

• Tolerance class: ISO 8062 CT5–CT6

• Fill time: <0.2 seconds

• Injection pressure: up to 120 MPa

• Porosity level: ≤0.5% (ASTM E505 X-ray verified)

Learn more about our metal casting process control for mechanically loaded lock assemblies.

Machining for Functional Features

Critical post-machined features included keyways, cam notches, mounting threads, and dowel holes. These operations were executed on 4-axis machining centers with automated part orientation and in-process gauging.

Machining operations:

• Bore tolerance: H7 (±0.015 mm)

• Threading: M3–M6 internal (ISO metric)

• Slot milling: ±0.02 mm positional tolerance

• Flatness of mating faces: ≤0.05 mm

Our post-machining services guarantee tolerance achievement for lock-and-latch interfaces.

Surface Treatment and Corrosion Resistance

Zamak parts were plated with satin nickel or chrome, while aluminum housings received anodizing. Optional powder coatings were applied based on enclosure color standards.

Surface finishing specs:

• Nickel plating: 5–10 µm, ASTM B456

• Chrome plating: mirror or matte finish

• Anodizing (Type II): 10–15 µm, dyed or clear

• Powder coating: 70–90 µm, RAL-compliant

See our full range of surface finishing solutions for industrial locking components.

Assembly, Testing, and Delivery

After finishing, components were assembled into functional lock subunits or packed as individual precision parts. Inspection included key rotation torque tests, thread gauge checks, and plating adhesion validation.

Assembly and QA:

• Torque test: ≤0.4 Nm rotational resistance

• Thread check: Go/No-Go gauge, ISO 1502

• Adhesion: ASTM D3359 (5B pass)

• Packaging: anti-scratch liners and ESD pouches

Our one-stop manufacturing services cover casting, machining, finishing, and subassembly for secure component integration.

FAQs

1. What material is best suited for high-tolerance lock cylinder manufacturing?

2. How are lock components cast to ensure tight bore and pin tolerances?

3. What finishing processes provide both durability and corrosion resistance?

4. How is rotational torque validated in cast locking assemblies?

5. What tolerances are required for post-machined cam slots and pin bores?