Not all applications require the cable or wire to be upset, as the molten alloy shrinks onto the strands, producing a strong locking action. In applications requiring high pull-off strength, the upset allows the molten zinc alloy to surround and shrink onto each individual cable strand. The emergency brake cable release consists of a 10,7 mm diameter barrel and a 9.3 mm diameter ball cast onto a 4 mm cable, centred to within 0,13 mm. Both terminations can withstand in excess of 4,400 N pull-off from the cable. The accuracy of the transfer mechanism in positioning the cable or wire in the cavity tool and the precision of the die casting process, eliminates variations.
Inspection is reduced, and rejects are virtually eliminated.
Equipment configurations IMA equipment is available in a variety of configurations, customized to the needs of the manufacturer. The ability of the Injected Metal Assembly process to eliminate manufacturing and assembly steps, and to improve quality and productivity, has enabled OEM and subcontract manufacturers to substantially cut production costs. Inventories of pre-manufactured components are eliminated, as is the overhead for equipment, supplies and floor space requirements for multiple assembly operations. The process also has the potential of reducing material costs as expensive materials are replaced with low-cost zinc alloy. The Injected Metal Assembly process has become a standard method of forming terminations on cable and wires for automotive, motorcycle and bicycle applications.