Zinc Die Casting
What is Zinc Die Casting
Zinc die casting is a process that involves melting zinc alloys (hence the name zinc alloy die casting) and injecting it into an already prepared die casting mold. Zinc alloys are applicable in part manufacturing due to their ductility, impact strength, and low melting point.
Benefits of Zinc Die Casting
Mechanical Properties
Zinc die cast alloys have high impact strength and exceptional ductility, a feature that is important for post casting machining. In environments with extremely low temperatures, zinc die cast alloys have impact resistance that exceeds that of aluminum and magnesium die castings. Additionally, the mechanical properties of zinc include resistance to corrosion, excellent firmness, and outstanding toughness.
Conductivity
Zinc die castings can conduct heat and electricity, which makes them ideal for devices that dissipate heat, such as heat sinks. The ability of zinc die castings to have thinner walls makes it possible for heat sinks to have a variety of fins and cooling pin designs for improved heat dissipation.
Surface Finish
The surface finish of zinc die casting was one of the reasons that it was first noticed as a viable production material. The smooth aesthetically pleasing finish of zinc die castings makes them ideal for applications that require functionality and appearance. Additionally, as a result of the zinc die casting process, castings require very little machining to achieve a high quality finish.
Faster Production
The cycle rate for zinc die casting is 150% to 200% faster than aluminum due to zinc's low melting point. With hot chamber zinc die casting, the melting and injection process are included in one mechanism, which increases efficiency and speeds up the die casting process. The high solidification rate of zinc die castings further reduces cycle time for higher productivity and significantly reduces casting costs.
Why choose us
Company technical strength
Company has advanced die-casting equipment and injection molding equipment, as well as a relatively complete enterprise management model. Our technicians can provide technical support in all aspects from product design, material selection to processing technology.
Product design
At MNW, you can choose the die-casting or injection molding process according to the size and shape of the parts you want. Our engineers give professional advice on materials, precision, and shell shape during design, and conduct simulations and tests.
Quality Management
The production of die-casting and injection-molded parts undergoes strict quality inspection, and a strict quality management system ensures stable and reliable product quality, meeting customer needs and industry standards. It has been widely recognized and praised by customers.
Supporting services
Offers a complete assembly capability, including manual and automatic assembly lines, to meet customers' needs. There is also online assembly testing and verification, committed to the goal of zero defect products, and continuous strict and reasonable process management.
Advantages of Zinc Die Casting
The list below shows different advantages of zinc die casting such as:
Zinc die-cast parts are more precise and stronger than aluminum die-cast parts.
Zinc casting parts have a low melting point and so these are easy to reshape/redesign if necessary.
It is easier to make thinner parts by zinc alloy die casting because of its good fluidity.
Manufacturers can make complex parts using zinc and the parts also have a smooth surface.
It is possible to do different surface treatments such as grinding, painting, electro-plating, etc. on zinc casting parts.
While casting the die is not subjected to too much heat because of zinc's low melting point. Thus, the dies have a longer service life.
Zinc alloy die casting parts have better mechanical properties than most other alloys.
Zinc die casting manufacturing process
Although manufacturing by zinc die casting has a long history, new developments in alloys and in die casting technology continue to make the zinc die casting industry relevant in today's modern world. Zinc die casting is a low-cost process that produces components with high precision and performance.
Zinc die casting is an exceptionally cost-effective manufacturing process. For instance:
Zinc die castings can be cast net-shaped, eliminating most if not all secondary forming operations.
The strength, bearing and wear properties of zinc die casting allow for consolidation of parts which reduces or removes the need for secondary inserts or fasteners.
Zinc provides the best surface finish of cast metals allowing easy application of decorative coatings by plating or painting.
The melting temperatures of zinc alloys are very low compared to other competing alloys such as aluminum, magnesium, copper, and steel components. This means:
Tooling (die) life is up to 10 times longer than other casting processes.
Cycle times are much faster due to zinc's low heat content.
Energy costs are lower.
the final view of project
Zinc alloys can be cast to very tight tolerances and specifications. Net shape casting eliminates the need for subsequent machining. Zinc alloys can be cast with the lowest draft angle and more easily cast with zero draft (in some designs). The dimensional stability allows easy maintenance of critical dimensions throughout a production run and allows for pressure-tight connections without gaskets.
In most applications zinc die castings are stronger and can have higher performance than many other alloys and processes. Depending on the zinc die casting alloy chosen, yield strength can range between 32-57 ksi (221-396 MPa), elongation can range between 1 percent to 13 percent, and hardness can be achieved up to 120 Brinell.
Due to Zinc's low melting temperature, applications at higher temperatures pose a challenge for zinc alloys; however, if the stress levels are low enough, zinc die castings may still be a cost savings option. In these cases, further investigation and discussion with a zinc die casting professional is suggested.
Density is only a perceived challenge for zinc. The density of zinc is 6.6 grams per cubic centimeter, which is approximately 2.5 times heavier than a typical aluminum alloy. In some cases, this weight difference is embraced and used to help stabilize (vibrational dampening) components or improved haptics (feel/sensory). However, today's engineers take advantage of zinc's combination of higher strength and fluidity to design thin wall and complex shaped components in zinc that compare in strength and weight to lighter alloys, but at lower manufacturing costs.
The complete process for hot chamber zinc die casting involves hot chamber filling, injection, high pressure, and cooling, all of which are completed in a rapid, cost effective production cycle.
Chamber Filling – When the plunger moves upward, it opens the intake port to allow molten zinc to fill the cylinder and gooseneck.
Injection – At a certain point, after the chamber is full, the plunger moves downward, pushing the molten contents of the chamber up through the gooseneck and nozzle into the sealed die. The pressure produced by the movement of the plunger ensures that the molten zinc is forced into every hole, crevice, and section of the die. This aspect of the process is the reason for the popularity of zinc die casting since it ensures high tolerances for intricate and complex parts.
Pressure – The pressure applied by the plunger continues even after the die is filled in order to achieve the highest possible quality in the completed part. The amount of pressure varies in accordance with the geometric features of the part as well as its size, contours, intricacies, and dimensions.
Cooling – As the plunger, through the molten zinc, applies pressure to the die, the molten zinc cools inside the die cavity. At the end of the cooling cycle, the plunger moves back, and the ejection portion of the die ejects the completed part.
Engineering Characteristics of Zinc Die Castings
Generally, zinc die casting tolerances are superior to those of aluminum and magnesium die castings. Zinc die casting can produce repeatability of less than ±0.001" for small components, often rivaling machining tolerances. Few other processes can easily achieve the same net shape performance. Many components are die cast to net shape and require no further machining. Due to zinc's ability to be cast with high accuracy, often complex assemblies are redesigned to consolidate component assemblies into a complex net shape casting, achieving substantial cost savings.
In general, zinc alloys machine rapidly, with minimal tool wear. Machining rates often rival those of free machining brass, and can be three times faster than for influences the selection of ZAMAK and ZA alloys over competitive materials. To review various machining guidelines for Zinc castings please visit our technical library.
Exceptional casting fluidity is displayed by all zinc die casting alloys, which provides superior thin-wall castability, regardless of the casting process employed. The recommended typical minimum wall thickness in zinc die castings has been reported to be 0.040" (compared to 0.060" in Aluminum die casting). However, due to todays improved die casting and alloy technology, die casting components have been produced with wall thicknesses as low as 0.008".
Draft angle is the taper on the surface of a die required to facilitate removal of the cast part from the die cavity. In general, zinc alloys can be die cast with less draft angle than competitive materials. In fact, zinc components can sometimes be cast with zero draft angles. This is usually not possible with aluminum or magnesium alloys. Zero internal draft permits net shape manufacturing resulting in lower cost production.
Zinc die casting alloys are very recyclable. According to the International Zinc Association (IZA), approximately 30 percent of first-use zinc production is made up directly of "reused zinc," such as scrap and oxides. At the die casting facility, production scrap is often remelted at rates of up to 50 percent, depending on size and shape of the scrap Zinc is a "self-cleaning" alloy. The dross that is formed during the process is lighter than the alloy, and therefore rises to the top of the melt and is easily skimmed. The resulting dross can also be recycled and re-used in various primary productions of zinc. Over the past decade, zinc recycling has doubled, and continues to grow in the industry.
As a professional plastic injection molding and die-casting manufacturer, MINDWELL exports all the injection molded parts and die-casting parts to countries all over the world. Our factory is ISO 9001:2015 certified and has perfect quality control procedures. We also have raw material certification, CE certification, SGS certification, etc.
Our Factory
Our company is an industry & trading company that covers research and development, production, processing, and sales. Our company has lots of excellent workers who design and make a mold to reach our customer's requirements.
FAQ
We're well-known as one of the leading zinc die casting manufacturers and suppliers in China. With 15 years' experience, our factory offers high quality zinc die casting made in China with competitive price. Welcome to contact us for custom service.
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