The demand of zinc cast parts is experiencing the explosive growth in morden industrial manufacturing due to common zinc alloys can be processed into versatile products. Die casting manufacturer spent lower cost to produce consistent high quality goods at very high efficiency, The process is hot chamber die casting, which has fast cycle time, lower heat energy consumption and precision dimension stability. The best castable metal alloy that it selects is zinc alloy material, which belongs to lower melting point metal.
Types For Common Zinc Alloys
Common zinc alloys have two main types of zinc alloy are basic of zin family, add other metal elements inside and create diversity zinc alloys. The main types have Zamak serial and ZA(Zin-Aluminum) serial.
Zamak Alloys
This kind of zinc alloys is Zn element is high content, up to 95% and other metal elements. They are medium weight and good mechanical properties. ensure the cast part dimensional stability. Less defective parts. lower metling points metal, can be finish vaccum die casting very easily.
| Items | Properties | Applications |
|---|---|---|
| Zamak 2 | Highest strength and hardness,excellent wear resistance and Good creep resistance | Gears, engine cover, locks and bear-loading mechanical structural parts |
| Zamak 3 | Excellent balance of strength and ductility, best castability and very good dimensional stability. | Consumer electrics, communication miniature parts and precision automotive components |
| Zamak 5 | Good hardness, good creep resistance and slight lower ductility. | medium sized cast parts or solid block parts, |
| Zamak 7 | Better for thin walls, excellent surface finish and better corrosion resistance | decorative parts, thin-walled parts and outdoor metal parts |
| Zamak 8 | Excellent creep resistance, better hardness and endure a bit higher temperature | high temperature parts, and precision mechanical parts |
ZA Alloys
This type of metal alloys is lower zin content of the range from 80-90% within ZA alloys, compare to Zamak serial, but more aluminum element content. ZA alloys are Lighter weight than Zamak serials. The cast parts have high strength structure and portability.
| Items | Properties | Applications |
|---|---|---|
| ZA -8 | Good strength and ductility balance, excellent creep resistance, Best fluidity among ZA serial. | precision cast parts, usb flash disk housings and automotive components |
| ZA-12 | Higher strength than ZA-8, better wear resistance and moderate ductility | medium sized cast parts or block solid parts and automotive components |
| ZA-27 | Very high strength and hardness, excellent wear resistance,high temperature resistance | transmmision parts, mechanical parts and gears |
How To Choose The Right Zinc Alloy For Zinc Cast Parts ?
Zinc die casting brings more benefits and convenience to many industries due to its lower cost raw material and mass production. Zinc die casting is ideal for miniature precision cast parts, because it ensure the precision dimension stability of the cast part and high quality mass production. The purpose of the cast parts decide which zinc alloy is selected.
Choose Cost-Effective Zinc Cast Parts
The zinc cast parts is considered of cost-effective, Zamak serial material is used. Depends on the application and function of the parts in real world, ts die casting technology chooses the specific zamak material to have a mass production at high volume. Since Zamak is obsolute lower melting point metal, under lower cost production, resulting in cheap metal parts. These cast parts are used for these common industries, such as communication, consumer electrics and fashion accessories etc. This type of zinc cast parts requirement should have the attention of the below.
- Initial Tooling Cost: Design and manufacturing of the die for the zinc cast parts
- Mass Production At High Efficiency: Manufacturing high performance cast die, and ensure more consistent high quality goods output, minimizing the defective goods.
- Strigently Quallity Control: Implement stringent quality management regulations, ensure and the quality of the lots of goods eligible, reduce the improper shipped goods as soon as possible.
- Zamak sustainable and reusage: zinc is sustainable and recylced, even though the scraps and waste after the process should be remolten and reused. and makes the waste reuage rate is up to 96%.
The Light Weight Zinc Cast Parts Is Purpose
These light weight zinc cast parts are often used on aircrafts and planes since the light weight of the cast parts, reduce the overall weight of the transportation tools. With excellent wear resistance and high hardness, ensure passage life safety.
In some specific conditions, these medium and small sized precision light weight metal parts are required, ZA serial material is applied. However the cost of production for ZA material is higher, comparison to Zamak one, the reason is ZA metal require more heat energy to melt, the process cost will become longer time.
Less lower cost ZA-8 is ideal material, with hot chamber die casting technology, they can be used as some assistant components on the planes and aircrafts or high precision and wear resistance automotive parts. Additionally, the post-processing for this type of cast parts become complex and longer time due to ZA belongs to the alloy metal that high aluminum element content, which is higher hardness and wear resistance, comparison to Zamak one.
Melting Common Zinc Alloys Rightly And Prepare Purified Molten Metal
Common Zinc alloys all belong to lower melting point metal material, at lower temperature these metals are melton completely. In the integrated reservior with the die casting machine, these zinc alloys are fulled and molten, overflowing the impurities and entrapped gas within the molten metal. Keep the steady temperature purified molten metal at 420℃ for good preparation for injection.
Once we find the molten metal is used for cast, frequently some defective cast parts are processed, the mold technician considers that whether the zinc alloy is high quality, exception of the design trouble of the cast die, they suggest replace high quality zinc alloy material and testing the cast part. mold technican should have a strong guarantee for steady temperature molten metal for high effetive injection.
