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Die casting is typically classified based on the heat and pressure required to inject molten metal into molds. However, it can also be categorized by the material used, with zinc die casting being one of the most popular due to its exceptional part strength. This article explores zinc die casting, its applications, and how it compares to other materials.
Zinc die casting involves melting zinc alloys and injecting them into pre-prepared molds. Known as zinc alloy die casting, this process is widely used in industries like automotive manufacturing due to its ductility, impact strength, and low melting point. Its low melting point allows the process to occur at lower temperatures, classifying it as a "hot chamber die casting process." This method offers advantages such as extended mold life, reduced retooling needs, and lower costs compared to other die-casting materials.
Preparing the Die: The mold is cleaned and lubricated to ensure smooth ejection of the cast part. It is then clamped under high pressure.
Injection: Zinc alloy is melted and poured into the injection machine's hot shot chamber, then injected into the mold at high pressure.
Cooling and Ejection: The molten zinc cools and solidifies in the mold, which is then unclamped to eject the finished part.
Trimming: Excess material is removed using tools like trim dies or saws. The trimmed zinc is recyclable, making the process eco-friendly.
Several zinc alloys are used in die casting, each with unique properties:
Zamak 2: Known for its strength and hardness, ideal for structural parts.
Zamak 3: Popular for its dimensional stability and compatibility with various finishes.
Zamak 7: Offers high castability and surface finish due to its low magnesium content.
ZA-8: A zinc-aluminum alloy suitable for hot-chamber die casting.
ACuZinc5: Researched by General Motors, it excels in hardness and creep resistance.
EZAC: Known for its high yield strength and creep resistance.
ZA-27: Contains 27% aluminum, making it lightweight yet strong.
At Eesson, we offer expertise in selecting the right zinc alloy for your project.
Easy Assembly: Parts are cast as single units, reducing assembly needs.
High Precision: Allows for thin walls without compromising strength.
Better Mechanical Properties: Stronger and more durable than aluminum or magnesium.
Complex Geometries: Ideal for intricate designs and moving parts.
Longer Tool Life: Molds last longer due to zinc's low abrasiveness and melting point.
Faster Production: High cycle rates and rapid solidification increase productivity.
Versatile Finishing: Options include plating, powder coating, and painting.
Prone to Defects: Rapid cooling can cause pores or blisters.
Heavy Parts: Zinc is heavier than aluminum, limiting its use in weight-sensitive applications.
Not Suitable for Small Batches: High initial costs make it better suited for mass production.
Applications of Zinc Die Cast Parts
Automotive Industry: For components like bearings and brake parts.
Electronics: In parts like switches and regulators.
Home Appliances: For items like handles and door locks.
Mechanical Sector: For engine parts requiring hardness and creep resistance.
Zinc die casting is a reliable method for producing strong, durable parts. For high-quality zinc die-cast components, trust Eesson's custom services. Our platform provides instant quotes, automated DfM reports, and seamless order tracking to ensure a smooth production process.
How Strong Are Zinc Die Casts?
Zinc alloys are 2.5X stronger than aluminum alloys.
Will Zinc Die Cast Rust?
No, zinc offers excellent corrosion resistance.
Can Zinc Die Cast Be Welded?
Welding is challenging due to its low melting point but possible with specific materials.
Room J757, No. 5358, Huyi Rd, Jiading, Shanghai, China
Room J757, No. 5358, Huyi Rd, Jiading, Shanghai, China
