To meeting the demand of the market in the world, more and more die casting manufacturers begin to engage in production of various metal die casting components, involves of aluminum alloy die casting, zinc alloy die casting , copper die casting and stainless steel die casting. But they found that most widest applications die casting are aluminum and zinc die casting process. Comparing between aluninum and zinc alloy die casting, Zinc alloy is better, advantages of zinc die casting is obvious.
What is die casting process ?
Die casting process is a metal casting process where forces molten metal into the designed casting die and formed. The casting die or mold may be hard steel, Cermaic, plaster and Sanding. Cavities in the die or mold are created using two pieces dies (like a permanent mold) that have been machined into the desired shape. The die casting process depends on different process technique in accordance with different material and craft process requirements. Some precision components should be cast by machines under high pressure, and ensure that the molten metal fills the cavities of the die or mold completely, produces high precision metal die casting components with fine surface finish. In another one, some die casting component can be cast by manual. So the surface of them is much rough and uneven area.
Manual Die Casting
Here Includes iron,copper, aluminum and gold material die casting, By using some rough mold to cast some general products.Manufacturer can make some simple molds with sand, ceramic, plaster ect. By manual, form some rough die casting parts, and need post-process in further.
Mechanical Die Casting
In order to ensure that die casting parts have complex geometries design and precision dimensions, Die casting manufcturer often introduce advanced die casting equipment and make high precision high quality steel mold, added with advanced die casting technique to produce a high volume cast parts with consistent quality in high efficiency. Mechanical die casting process is higher effective manufcturing process and also create more smoother die castings surface finishing, compare to manual die casting process. Two main types of mechanical die casting processes are included.
Hot-Chamber Die Casting
The injection system is submerged in the molten metal pot. It is primarily used for metals with low melting points like zinc, magnesium, and lead. The die casting process is favor of producing high precision die casting components with fine surface finish. Such as zinc alloy die casting parts.
Cold-Chamber Die Casting
The molten metal is ladled into a cold chamber where it is then injected into the die under high pressure. Metal melton pot is apart from the die casting machine, becase the pot high temperature affects the machine temperature rigidly. This is suitable for metals with higher melting points, such as aluminum, copper, and some magnesium alloys. The die casting process is suitable for making aluminum die casting parts.
Advantages of Mechanical Die Casting
High Precision and Accuracy: Produces parts with tight tolerances and intricate geometries.
Smooth Surface Finish: A Fine surface finish, uniform surfaces due to high precision casting die.
Fast Production Rates: mass production, offering a rapid cycle time for high-volume output. makes fast production rates
Material Efficiency: Reduces waste, as scrap metal can often be recycled and sustainable in environmental protection.
Die casting is popular because die casting components have various different functionalites and applications. Some common, unstrict dimensions parts can be made by manual, their process is simple and rough. However some high precision and accuray dimensions components should be made by mechanical die casting process. Die casting process is broad process, which is decided by client requirements completely.
Advantages of Zin Die Casting
Zinc die casting, especially through processes like die casting, offers several advantages due to the unique properties of zinc,cost-efficiency production and sustainability. Here are the key advantages of zinc casting.
| Advantages In Several Aspects | Details |
|---|---|
| Excellent Fluidity and Malleability | Zinc has a low melting point (around 419°C), making it highly fluid when molten. This allows for intricate designs and complex geometries to be cast with precision, especially in die casting. |
| Cost Efficiency | Zinc die casting, particularly in high-volume production, is cost-effective. The low melting point reduces energy consumption and shorter each product cycle during production, and the longer mold life associated with zinc casting reduces tooling costs. |
| Dimensional Stability and Precision | Zinc Die casts are known for their excellent dimensional accuracy, meaning that parts require minimal post-processing or machining. This leads to better-fitting parts with tighter tolerances. |
| Superior Surface Finish | Zinc parts often have smooth surface finishes directly from the mold. This reduces the need for additional finishing operations like polishing or plating. |
| Strength and Durability | Zinc alloys exhibit excellent strength and durability, making them suitable for structural components. Some zinc alloys, like Zamak, combine strength with toughness and resistance to wear and impact.Zinc has inherent corrosion resistance, especially when alloyed with other metals. This makes zinc-cast components ideal for outdoor or harsh environments. |
| Recyclability | Zinc is 100% recyclable without losing its properties, without any emmition of carbon, making zinc casting an environmentally sustainable option. |
| Low Shrinkage | Zinc alloys typically have low shrinkage during cooling, which helps in maintaining the accuracy dimensions and integrity of the final cast product. |
Overall, zinc die casting combines the benefits of cost-effectiveness, precision. making it a preferred method for manufacturing a wide range of components. This is just advantages of zinc die casting.
