Die casting is an innovative and excellent means of creating various intricate metal components required in todayโs leading industries, including automotive, robotics, medicine, aerospace, and electronics. It involves forcing molten metal into a mold under high pressure to form a desired shape.
Metals such as aluminum, zinc, magnesium, copper, brass, and tin are popularly used for die casting, considering that most industrial tools are made from these common ones. However, zinc alloys are the chosen metal for casting when manufacturing vital and complex metal parts.
SANON is a top zinc die-casting company in China that designs and manufactures various machine parts used in the automotive and electronic industries. In this guide, we will examine zinc die casting, the process, its benefits, and the various zinc alloys used for die casting.
What Is Zinc Die Casting?
Zinc die casting is a process in which zinc alloys are melted and injected into a prepared die-casting mold that is already shaped and sized to the dimensional part of the metal component to be manufactured. Due to their strength, malleability, and low melting point, zinc alloys are a great choice in the manufacturing of machine parts and die castings.
Among the various metals used in die casting, zinc is the easiest to mold and also the most abundant. It is characterized by its brittle, silvery-white color, often with a blue tinge. When zinc is exposed to air, its color element quickly fades.
If your business requires the use of zinc-made parts, itโs essential to know that the zinc die-casting alloys are made of 78% zinc, and the remainder components are composed of magnesium, tin, aluminum, copper, and lead, which are necessary to achieve a high-impact and quality die-cast.
The Zinc Die Casting Process
Zinc alloy die castingย is performed under low heat due to its low melting properties. Hence, a hot chamber die-castingย process is used for zinc. Zinc allows manufacturers and engineers to design intrinsic tools and machine parts that cannot be designed using other alloyed metals.
Zinc is ideal for designing parts with thin walls and complex and intricate geometries due to its structural integrity, bearing, and wear properties. Similar to how other metals are cast, a zinc die cast follows the same process, with slight altercations. The processes are divided into four, viz:
Process 1: Preparing the Die
Before the casting process is initiated, the dies are carefully cleaned and lubricated to enhance the smooth ejection of the casted part after cooling. The die-cast mold is also cleaned to eliminate every impurities. Afterward, the die is clamped under high pressure.
Process 2: Injection
Since zinc casting is a hot chamber casting, the zinc alloy is melted and poured into the injection machineโs chamber. The melted zinc is then injected into the die-cast mold at high pressure.
Process 3: Cooling & Ejection
Cooling is a necessary step in a zinc die-cast. It allows the zinc to effectively take the shape of the expected mold design. After the zinc has cooled and solidified, the mold is unclamped to eject the cast zinc out of the die.
Process 4: Trimming
Molten metals often have edges and parts that need to be trimmed. Hence, trimming helps remove the excess metals to achieve the desired shape and size. Zinc die-casting manufacturersย use a trim die, saw, and other tools to perfectly trim the die-cast mold.
Zinc alloy die casting produces limited waste, as the trimmed zinc cast can be recycled and reused to mold other machine parts.
Types of Zinc Alloys Used for Die casting
Various zinc alloysย are used forย die casting, and these alloys contain a small percentage of other metals, such as aluminum, copper, magnesium, tin, iron, and lead. The various metal combinations help enhance and change the properties of zinc during the die-casting process.
Each zinc alloy has distinct properties, and the choice selected for casting depends on the properties, characteristics, and industry in which the cast is required. At Sanon Casting, we offer a selection of zinc alloys and select the best fit for your project. A summary of the zinc alloy we use for die casting includes:
Zamak 2
Zamak 2, also known as Kirksite, is the hardest and strongest alloy in the Zamak category. Due to its high structural integrity, it is mostly used in the automotive and mechanical industries.
Zamak 3
Zamak 3 is known for its excellent dimensional stability and molding efficiency. Combined with its mechanical and physical properties, it is highly compatible with various finishing touches applied to a zinc die cast, such as plating, chromate treatments, and painting.
Zamak 7
Zamak 7, or Zinc Alloy 7, has lower magnesium components and impurities than other zinc alloys. Due to its composition, Zamak 7 is essentially used to create parts requiring high stability.
ZA 8
The ZA-8 is composed of zinc and aluminum. It is popular among the Zamak family for its aluminum content and is highly compatible with making machine parts using hot chamber die cast.
ZA 27
This zinc-aluminum alloy contains 27% aluminum, making it the zinc alloy with the most aluminum concentrate in the Zamak family. Due to its lightweight, strong, and durable characteristics, it is used in the molding of parts with structural integrity.
AcuZinc5
AcuZinc5 is highly revered for its sturdiness, creep resistance, and lubricity. It is often used in die casts requiring parts with high structural integrity under hot conditions.
Benefits of Zinc Die Casting
There are many advantages to using zinc alloys in die-casting compared to other die-cast materials. Zinc alloy is significantly regarded in die casting for its mechanical properties, cost-effectiveness, and solid and durable characteristics. Below are the expected benefits of zinc alloys in casting:
High Precision and Easy Assembly
Due to its strong properties, zinc alloy allows for reducing the wall thickness of a mold. When designing metals with thin walls, zinc can maintain their structural integrity and reduce die-casting costs. Moreover, the entire zinc casting is cast as a single unit, allowing easy assembly.
Complexity of Cast Geometries
Zinc has a unique breaking and wear property that enables it to be used as bushings for moving structures. Due to its compatibility with other materials, zinc can also be used to mold parts with complex geometries.
Possesses Better Mechanical Properties
Strength, corrosion resistance, toughness, and durability are among zincโs mechanical properties over aluminum and magnesium, which help enhance its use in making machine parts with solid properties.
Improves Production Efficiency
Zinc alloysโ cycle rate is higher than that of other die-casting materials. This is because zinc has a low melting point, enabling it to be cast using the hot chamber die-casting process, which significantly increases the number of parts produced and cuts down casting costs.
Enables Customized Finishing Options
Zinc alloys enable manufacturers and engineers to customize machine parts with aesthetic finishing options such as plating, painting, electroplating, powder coating, and anodizing. These finishing touches help increase the durability and corrosion resistance of the molded parts and their uniqueness for the required application.
Demerits of Zinc Die Casting
While zinc alloys have numerous benefits, a few demerits can be obtained when zinc is used for die casting. The disadvantages include:
Prone to Casting Defects
The zinc die-casting process involves filling the mold quickly and requires quick cooling. However, this can cause defects, such as blisters and pores, to the mold, especially when thereโs a late gas discharge. These kinds of defects can reduce the quality of the casting process.
Suitable for Large Production Only
Zinc die casting is primarily used to mass-produce parts of a machine or tool, and it often costs more to die cast than other materials. Hence, it is not suitable for the production of parts in small baths.
Common Applications of Zinc Die Cast Parts
Zinc die-cast materialsย offer valuable applications in various industries. Some industries whereย zinc alloy die castingย is required include:
Automotive Sector
Zinc alloys are preferred in casting interior components in many automotive industries due to their strength and durability. They are essentially used in molding automotive parts such as brake parts, bearings, and steering.
Mechanical Sector
Zinc alloy castingโs creep resistance and hardness are evident in its use for making engine parts in the mechanical sector. These properties make zinc die casting preferable to aluminum materials.
Electrical Sector
Zinc die casting is used to manufacture components in the electrical sectors, such as ceramic-encased resistors, toggle switches, energy regulators, and wall clocks. Zinc is preferred for manufacturing these components due to its dimensional stability, essential in making electronic parts.
Home Appliances
Zinc casting is used to manufacture home appliances, such as door locks and handles, furniture inserts, shoe buckles, belts, and key chains. Zinc alloysโ dimensional stability and strength make them suitable casting materials for home appliances.
Cutting-edge Zinc Die Casting Services in China
Zinc die castingย is a vital manufacturing process at the heart of various industrial projects. They are famous for their strength, corrosion resistance, and durability. Although there are a variety of zinc alloys in the world today, itโs important to know the most suitable one for your project. With this, you need the eyes of an excellent and experienced die-casting manufacturer.
At SANON CASTING, we use several zinc alloys for die castingย and can provide you with the most suitable one for your project, helping you understand their significant properties. If youโre looking for the service of a zinc die-casting manufacturer in China, we are your best choice. Request a quoteย from us today, and letโs bring your project ideas to reality.
