Zinc die casting is the most common metal die casting process in modern industrial manufacturing. It means a complicate process, which the molten zinc alloy is injected into the high precision steel mold. Then having a quick cool and solidification, the mold opens automatically, eject the shaped zinc part out from the mold. Similar with aluminum alloy die casting, but sole different from which , requires the support of hot chamber die casting technique.
Understanding Zinc Die Casting Process and Applications
Let us to understand zinc die cassting further more from its unique advantages and applications of zinc die casting parts, makes us to have a general overview for zinc die casting, and handle the quality of zinc die casting process well, produces more metal cast parts to meet the requirements of many industrial applications.
Step By Step Zinc Die Casting Process
Step 1
Die Preparation
The die will be designed and manufactured after our engineers and designer collabrate with the client. For best option of high quality steel, through various precision machining process, process high precision cores structure and cavities suface finish, and preheat the die, and ready for quick part casting.
Step 2
Melting Zinc Alloy And Inject The Metal Part
Zinc alloy has a lower melting point, and needs limited heat energy to melt. So the integrated furnace with the hot chamber die casting mchine can melt the zinc alloy in short time and maintain steady temperature molten zinc. With the unique injection mechanism, that is gooseneck injection mechanism, quickly inject the molten zinc alloy into the preheated die.
Step 3
Cooling And Solidification
After the molten zinc alloy is injected into the preheated die under high pressure. The die casting machine can cool the die in a few seconds and solidify the zinc alloy inside the die. Since zinc alloy has a lower melting point, the cast pat can shape in shorter time and ensure an accurate dimension.
Step 4
Ejection & Trimming
The cast part is solidified, the die casting machine will open the die, and half the cores and cavities of the die. The shaped cast part is ejected out from the die. The workers will have a further post process, and trims the flashes on the part line and burs on the surface of cast part.
Step 5
Conduct The Strict Quality Control
The semi-finished parts for trimming and deburring will be all check by our quality clerk, and pick out the defect parts among the mass cast parts, sperate into the good parts and ungood parts. And package the good parts and store the transfering warehouse, and wait for further die casting surface finishes.
Applications For Zinc Alloy Die Casting Parts
Depends on the unique metal properties of zinc alloys, Zinc alloy die casting parts have been widely used across many industries. But also their lower production cost and flexible design gemotries meets diversity requirements of industrial applications. These zinc alloy casting parts also support sustainability and follow environmenta l management regulations. the below categries from several sectors, we have a detail descriptions for each one.
| Industrial Categories | Detail Applications |
|---|---|
| Automotive Industry | Automotive Parts need more precision and strong corrosion resistance, Zinc alloy just fits the specific requirements. So they may be used forEngine & Transmission Components, Safety & Electrical Systems, Interior & Exterior Hardware. |
| Electronics & Electrical Devices | Zinc alloys is suitabe for small size casting, and has a wide range applications for Electrics and compact device. include of Consumer Electronics, Power & Electrical Systems, Telecommunications. |
| Consumer Goods & Hardware | For lower production cost, many consumer goods are made of zinc alloys. They contain Fashion & Accessories, Household & Kitchenware, Toys & Recreational Equipment ect. |
| Industrial & Machinery | With a strong strength, zinc alloy is cast into many industrial equipment parts and mechanical parts. They include of Fluid Handling Systems,Fasteners & Hardware, Tooling & Equipment. |
| Medical & Healthcare Devices | Some special zinc alloys fit medical devices parts, like Surgical Instruments, Medical Device Housings, Prosthetics & Orthopedic Devices. |
| Aerospace & Defense | ZA alloys are used for precison parts in aerospace and defence. For example, Avionics & Instrumentation, Defense & Military Equipment. |
Advantages For Zinc Die Casting
Cost-Effectiveness
Zinc alloys are generally less expensive. Zinc Die casting offers rapid production cycles, and employing mass production with high repeatability and minimal waste due to zinc material special properties. However A professional zinc casting manufacturer uses zinc die casting in high efficiency to raise company profits. Certainly zinc die casting tools have a longer lifespan due to lower operating temperatures, reducing overall production costs.
Design Flexibility
Zinc alloy die casting can achieve intricate and thin-walled designs with high precision. A proficient product design team will can design and make complex geometies according to client’s requirements. It allows for smoother surface finishes, reducing or eliminating post-processing like polishing or machining. Excellent for creating miniature components with tight tolerance and accuracy dimensions.
Mechanical Properties
Zinc alloys are impact-resistant and lighter than stainless steel, reducing the overall weight of the product. Also zinc alloy has a strong strength and corrosion resistance. So many automotive components are made of zinc alloys, and improve fuel-effective and electronic vihecles overall weight and increasement of running performance.
Corrosion Resistance
Zinc alloys offer natural corrosion resistance,and less rust produced, So zinc die casting components can be exposed on moisture air and corrosion environments for a long time. Especially when plated or coated, though less than stainless steel in extreme environments.
Recyclability
Zinc alloys are highly recyclable, and sustainable and support environment protection and confirm international green eco-friendly standards. So the special metal alloy can be reused with less waste, eliminate carbon emmition to enviroment, and the zinc die castings lost its functionality, and they will be remolten and cast other die castings to use.
