The Zinc die casting process is widely used in the construction and industrial fields to manufacture parts, but the most common application is in the automotive industry. In fact, automobiles have different parts that can be manufactured by the die-casting process, so that the modern die-casting process was originally started in the automobile industry.
In the casting process, there is usually no need for further processing after casting: not only is the accuracy as high as 99.8%, but the cast products can also be used for raw materials because they have a pleasant finish. The use of zinc die castings in the automotive industry accounts for almost 28%, followed by construction and hardware.
Zinc has become one of the most important metals in the automotive parts industry, especially for door lock housings, pawls, retractor gears and pulleys in seat belt systems, as well as camshafts and sensor assemblies. By using this metal and its alloys, strength, ductility and ductility that cannot be achieved by other materials can be achieved.
In addition, zinc is the right choice for obtaining high-quality aesthetic parts, with tight tolerances that other materials cannot achieve, and for obtaining embossing and grooves for mechanical or gear parts.
Automotive zinc die casting
As mentioned earlier, the automotive industry is the most common application of die castings: by using zinc and its alloys, parts that can achieve high aesthetic quality, with strict and narrow tolerances on shape and shape can be produced. Zinc alloys also have many advantages, such as enhancing the already impressive zinc anti-corrosion properties, and can also be used for electroplating.
Below, you can find some examples that can be produced with galvanizing:
Interior aesthetic parts
Engine and other components under the hood
Power steering system
Brake parts and systems
Air conditioning components and systems
Parts in the seat belt system
Climate control module
In the next paragraph, we will list the advantages of zinc alloys.
Advantages of zinc alloy
Zinc alloys in die casting can develop products and simplify production, thereby providing durable end products. The strength, ductility and stability of zinc enable experts to obtain better and more durable products. It is this high ductility that makes zinc ideal for die casting processes where pressure and expansion must be maintained without cracking. Other advantages of zinc alloys can also be used for die casting, such as:
Electrical conductivity and thermal conductivity
Low raw material cost
Strong stability, so that the lasting final product has high-quality finishing performance
Thin walls: they help to improve the corrosion resistance of the final product and improve its durability in harsh environments
Small parts economy
Low melting point, which means less energy is required for production
Longer mold life
Complex geometry and high-quality finishing: By using zinc, complex, thin-walled and technically demanding parts can be cast with high precision
High-quality coating and chrome plating: zinc die castings are suitable for electroplating
Zinc and other materials
Each alloy has its own characteristics in terms of physical and mechanical properties: these factors are crucial for determining the life, strength and function of the product. The complexity of the product, the wall thickness and the required accuracy will affect its castability: these elements should be regarded as the main points to better organize the production of die casting.
The method of die casting differs depending on the design application and metal selection: hot or cold chambers are just two of them. Hot chamber die casting is ideal for low melting point metals such as zinc or magnesium, while cold chamber processes are used to melt higher temperature alloys such as aluminum.
Zinc alloys compete with other materials in the die-casting industry: aluminum, cast iron, machined brass, machined steel and magnesium, and zinc is zinc, the most commonly used metal in die-cast products. Choosing an alloy is a difficult task: the die casting machine must analyze its application, material density, tensile strength, yield strength, melting temperature and elasticity to obtain better results under all its functional and aesthetic requirements.
1. Zinc alloy and aluminum
One of the main differences between aluminum and zinc alloys is that zinc has a low melting point and requires lower pressure during die casting. For these reasons, zinc alloys are the easiest alloys to cast. The lower melting temperature can make zinc die casting molds have a longer service life, and because the molds are expensive, long-term use of molds is a cost-effective method to achieve high output.
Moreover, zinc can be cast with HPDC, which is cheaper than the cold room process. By using HPDC, the production speed can be increased. On the other hand, aluminum alloys are usually cast using a cold chamber process, which has a lower productivity than the hot chamber process used for zinc.
In addition, zinc is more suitable for very detailed castings, and almost no machining or finishing work is required after ejecting the part from the mold: low pressure and low melting point reduce the thermal shock during the casting process, making the surface of the part smoother. In addition, excellent zinc formability and machinability have cost advantages in finishing and assembly operations.
Aluminum die-casting has another disadvantage: it tends to generate sparks when it strikes iron or steel. It is forbidden to use in dangerous environment which may produce explosive atmosphere. In contrast, zinc is a non-sparking material, so there is no such risk, even in those environments.
Generally, zinc has better accuracy, smaller draft angle, smaller and longer core hole, longer tool life, possible thinner wall, excellent tensile strength, and better processability Performance, better formability, lower casting costs, excellent pressure resistance, more finishing options compared to aluminum, it is a non-sparking material.
2. Zinc alloy and cast iron
Compared with cast iron, zinc has lower casting costs, higher accuracy, and superior thermal and electrical conductivity. However, it is difficult to compare cast iron with zinc alloys, because cast iron has a wide variety of materials, and each material has different properties, so they cannot be strictly defined.
3. Zinc alloy and machined brass
Compared with machined brass, zinc alloys have lower process costs, lower material costs, less process scrap, and equivalent or higher tolerances. As before, the term brass refers to multiple casting materials with many different mechanical properties, so it is impossible to define each material.
4. Zinc alloy and machined steel
Compared with machined steel, the processing cost of zinc is lower, the corrosion resistance is higher, and the same or higher tolerances can be achieved.
5. Zinc alloy and magnesium die casting
One of the main differences between magnesium and zinc alloys is that zinc alloys require lower pressures and temperatures for casting. Compared with magnesium, magnesium alloys require special corrosion resistance and surface treatment. Zinc alloys have excellent corrosion resistance and a surface just after being ejected from the mold.
The density of magnesium is very low, just like zinc, magnesium alloys can also be die-cast by HPDC: therefore, their cycle time is faster than aluminum. However, zinc is superior to magnesium in all aspects.
Compared with magnesium, zinc has lower processing cost, lower draft angle, higher accuracy, excellent rigidity, excellent tensile strength, better corrosion resistance, excellent formability, longer Tool life, more finishing options, and it is a non-sparking material.
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