Welding Zinc Die Cast
In the past, only a few real experts could weld zinc die cast. Using our Super Alloy 1 this formerly impossible job can be easily performed by any auto body man or repairman.
An expensive grille or part can be salvaged for a few cents. If the fractured part of the die cast is thin, it is not necessary to bevel it. If it is over 1/8" thick it should be beveled. The parts should then be aligned and supported.
Elaborate support is not necessary due to the low heat of Super Alloy 1, even though zinc has very little strength when hot. Chrome plated parts should be bevelled from the side which is not visible on the completed operation. When the bevel is filled in, a good weld is formed and the chrome plating acts as a support during the welding. Super Alloy 1 is applied at such a low heat that the plating is not damaged.
The important point to remember is to use a small tip, two sizes smaller than if the part were steel. The flame should be only slightly excess acetylene. Very little preheat is required but it is important to hold the flame very close to the work.
Apply Super Alloy 1 flux liberally with a brush. Super Alloy 1 simplifies the joining of white metal because it is applied far below the melting point of the white metal, and yet produces a sound weld exceeding the strength of the base metal.
It is not necessary to flick the torch away momentarily at the precise moment the base metal starts to melt with Super Alloy 1 because it is applied at such a low temperature.
With this procedure practically all zinc die cast parts can be readily salvaged by panel beaters and maintenance men who are not expert welders.
