Diecasting-mold. com and other businesses across a wide range of industries make extensive use of zinc die casting, which is a manufacturing process that demands precision. A comprehensive guide to designing and manufacturing parts through zinc die casting, this guide covers everything you need to know about the process.

Die casting with zinc: what is it? 

In the process of zinc die casting, molten zinc alloy is injected into a steel mold while the mold is under intense pressure. Within the mold, the metal undergoes a process of solidification and cooling, which results in it taking on the desired shape with remarkable precision and surface finish. Because of their low melting temperature, zinc alloys are particularly well-suited for die casting when compared to other materials.

Characteristics of Zinc as a Material

When it comes to die casting, the zinc alloy that is utilized the most frequently is Zamak-3. This particular alloy is composed of 95-97% zinc, 0.5-3% aluminum, and 0.05-3% copper. All of the following characteristics are exhibited by this alloy:Power-to-weight ratio: exceptionally highExceptional resistance to corrosion715 degrees Fahrenheit (380 degrees Celsius) is the melting point. fluidity for the purpose of filling difficult cavitiesBetween 25 and 45 ksi (or 170-310 MPa) of tensile strength? There are also other zinc alloys available, such as Zamak-1, 2, 4, and 5, which are used for specific applications.

Zinc die casting: design considerations to take into account

When designing parts for zinc die casting at diecasting-mold. com, some of the most important considerations to take into account are the wall thickness, draft angles, ribs, corners, gate locations, and machining allowances. Wall Thickness It is important to maintain a steady thickness of 0.04-0.25 inches in order to achieve optimal filling without any defects. Steer clear of sudden shifts that could disrupt the flow of metal. Draft Angles Incorporate draft angles ranging from three to ten degrees in order to make ejection from the die easier. It's possible that internal features will require a full draft. In order to reinforce thin walls and complex geometry, ribs are utilized. Bosses are also utilized. When designing ribs, pay attention to draft and the impact it has on cooling. In order to lessen the amount of stress that is concentrated and the amount of ejection forces that are exerted, corners and radii should be around 0.04 inches. Both the Gate and the RunnersThe gates should be placed in low-stress areas that are away from critical features. Streamline the flow of material by reducing the number of runners and risers. The allowance for machiningTake into account a machining tolerance of +/- 0.010-0.030 inches, depending on the complexity of the part, its size, and the surface finish that is required.

Zinc Die Casting Offers Numbers of Benefits

Compared to other methods, such as aluminum die casting, this method offers a number of advantages, including precision, strength, an aesthetically pleasing surface finish, versatility, and increased cost savings.

Examples of Zinc Die Casting's Applications

The use of zinc die casting for structural components that require mechanical strength, dimensional accuracy, and intricate details is common in a variety of industries, including automotive, hardware, appliances, electronics, medical devices, tools, and household items.

At diecasting-mould.com, the zinc die casting process is described. Our facility provides comprehensive zinc die casting services, which include engineering and tooling development, as well as zic die casting products that are produced in high volumes. Presses that are state-of-the-art, automated trim/eject machines, and heat treatment that is performed in-house all contribute to excellent process control and precision.