TangSheng Hardware Technology, as one of professional die casting manufacturers, mainly offter two types of metal die casting parts, include of zinc alloys and aluminum alloys die casting processes. the die casting parts that we produce have been used for automotive, communication, medical and consumer electrics industries. We have been learned more about zinc and aluminum alloys properties, and choose best composition alloy for functions and applications of part, provided high precision metal die casting parts across many industries. These common aluminum and zinc alloys can be processed into high precison parts by different casting technique respectively. They are Hot chamber die casting and Cold chamber die casting processes. we will observe the benefits applicable to each alloy.
Aluminum Alloys for High-Precision Casting
Common Aluminum Alloys Items Run At TangSheng
| Alloy | Composition | Properties | Applicatons |
|---|---|---|---|
| A380 | ~8.5% Si, 3.5% Cu, <1% Fe, <3% Zn | Excellent fluidity, good strength, and pressure tightness | Engine brackets, gearboxes, electronic housings |
| A383 | ~10-12% Si, 2-3% Cu | Improved die-casting performance, reduced hot cracking | Thin-walled components, automotive parts |
| A360 | ~9-10% Si, 0.4-0.6% Mg | Superior corrosion resistance, good pressure tightness | Marine components, hydraulic systems |
| A413 | ~11-13% Si | Excellent castability, high impact resistance | Complex thin-walled parts, optical mounts |
| AlSi7Mg (A356, A357 – T6 heat-treated) | ~7% Si, 0.3% Mg | High strength, good weldability, and machinability | Aerospace, high-stress structural components |
Zinc Alloys for High-Precision Casting
Common Zinc Alloys Items Run At TangSheng
| Alloy | Composition | Properties | Applicatons |
|---|---|---|---|
| Zamak 3 | ~4% Al, 0.03% Mg, <0.1% Cu | Best balance of strength and ductility, excellent castability | Gears, connectors, consumer electronics |
| Zamak 5 | ~4% Al, 1% Cu, 0.03% Mg | Higher strength and hardness than Zamak 3 | Automotive components, precision hardware |
| Zamak 7 | ~4% Al, 0.005% Mg, <0.1% Cu | Improved corrosion resistance, minimal intergranular corrosion | Medical devices, outdoor equipment |
| Zamak 8 | ~8.4% Al, 1% Cu, 0.02% Mg | High strength, good wear resistance | Bearings, bushings, high-load parts |
| ACuZinc (Zn-Al-Cu-Si) | ~5% Al, 2.5% Cu, <1% Si | Superior creep resistance, high-temperature stability | Die-cast automotive parts, industrial fittings |
Aluminum Alloys Vs. Zinc Alloys
Aluminum Alloys Pros And Cons
Advantages Of Aluminum Alloys
- Lightweight: a low density (~2.7 g/cm³), making it ideal for aerospace, automotive, and portable electronics.
- Good Strength-to-Weight Ratio: offer strength comparable to steel but at a fraction of the weight.
- Excellent Corrosion Resistance: Naturally forms a protective oxide layer, reducing rust. Alloys like A360 (Al-Si-Mg) perform well in marine environments
- High Machinability: Softer alloys (e.g., A380, 6061) are easy to machine, reducing tool wear and production costs.
- Good Thermal & Electrical Conductivity: Used in heat sinks, electrical enclosures, and LED housings.
- Castability & Fluidity: flow well in molds, allowing complex, thin-walled designs.
- Recyclability: Aluminum is 100% recyclable without quality loss, making it eco-friendly.
Disadvantages Of Aluminum Alloys
- Lower Hardness & Wear Resistance: Softer than steel or zinc, leading to wear in high-friction applications.
- Higher Cost Than Zinc Alloys: Raw material and energy costs are higher than for Zamak alloys.
- Lower Dimensional Stability: Higher thermal expansion can cause warping in tight-tolerance applications unless properly heat-treated.
- Porosity in Castings: Hydrogen absorption can cause voids, requiring vacuum casting or degassing.
- Surface Finishing Challenges: Can oxidize during anodizing or plating, requiring careful pretreatment
Aluminum Alloy Die Casting Parts , Very Light Weight, its surface finishes are diversity, Easy surface finishes are anodized, painting, powder coated. But electroplating is very difficult due to aluminum alloy properties, and belong to porosity metal, more pretreating processes for electroplating.
Zinc Alloy Die Casting Parts, belong to high precision metal components , and used for a wide range, from automotive to communication industries. The casting parts have a steady dimensions and good strength integrated structure, with strong corrosion resistance.
Zinc Alloys Pros And Cons
Advantages Of Zinc Alloys
- Superior Castability & Fluidity: Zamak alloys (e.g., Zamak 3, Zamak 5) flow exceptionally well in molds, enabling thin walls (as low as 0.5mm)
- Excellent Dimensional Stability: Low shrinkage (~0.7%) compared to aluminum (~1.3%), making zinc ideal for tight-tolerance parts (e.g., gears, connectors).
- High Strength & Hardness: higher strength, higher tensile strength, strong resists wear.
- Smooth As-Cast Surface Finish: less post-machining/polishing than aluminum.
- Faster Production Cycles: lower temps (~385°C/725°F vs. ~660°C/1220°F for Al), allowing quicker die-casting cycles and energy savings.
- Cost-Effective for Small, Complex Parts: The lower melting decide zinc alloys to cast small sizes casting parts, but the zinc die castings are high precision.
Disadvantages Of Zinc Alloys
- Heavy: 2.5x denser than aluminum, making it unsuitable for weight-sensitive applications.
- Limited High-Temperature Performance: Loses strength above ~120°C (250°F), not suitable for engine components or hot environments.
- Corrosion Resistance Requires Plating: Bare zinc in humid or salty environments requires equires chromate plating, powder coating, or nickel finishes for protection.
- Brittleness in Certain Alloys: Zamak 7 and ZA-12 are more brittle than aluminum, risking fracture under impact.
- Not Ideal for Large Parts: Higher density makes large zinc castings unwieldy and expensive (aluminum or magnesium are better for big components).
