Padlock Body Brass Die Casting: Manufacturing and Security Testing
Padlock Materials
Padlock manufacturing uses brass C36000 for premium bodies, zinc ZAMAK 5 for mid-range and hardened 4140 steel for high-security shackles. Brass offers corrosion resistance and accepts fine surface detail for logos.
Shackle options: hardened steel for security, stainless 304 for marine, brass for decorative. Cylinder mechanisms from precision brass components.
| Component | Material | Process | Security |
|---|---|---|---|
| Body Premium | Brass C360 | Die casting | Medium-High |
| Body Standard | Zinc ZAMAK5 | Die casting | Low-Medium |
| Shackle | Hardened 4140 | Forging+CNC | High |
| Cylinder | Brass | Swiss CNC | Medium |
Die Casting Process
Hot chamber for zinc (387°C, 15-30s cycle). Cold chamber for brass (950°C, 30-60s cycle). Zinc offers faster cycles and longer mold life. Brass provides superior strength. Both use H13 tool steel with nitriding.
Mold design: 0.5-1° draft, conformal cooling, effective venting for complete fill of complex body shapes.
| Parameter | Zinc ZAMAK5 | Brass C360 |
|---|---|---|
| Melt Temp | 387°C | 950°C |
| Cycle | 15-30s | 30-60s |
| Mold Life | 500k+ | 100-200k |
| Surface | Excellent | Good |
Security Testing
Shear test: >3,000N for body. Torque: >1,000Ncm for cylinder. Pull test for shackle per ANSI Grade. Cycle test: 100,000+. Key shear line tolerance: ±0.05mm between cylinder and body.
Drill resistance testing for high-security padlocks. Hardness test for shackle material. Pick resistance evaluation per industry standards.
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