Zinc Die Casting
Zinc is among the most valued metals because of its unique properties and paramount applications. Its usefulness extends from medical, biological, and electrical aspects to die metal casting. In addition, zinc is regarded as one of the easiest metals to cast due to its low melting point (419°C). In die casting, zinc was introduced in 1914, and since then, it has progressed exponentially.
Die casting can be defined as a metal casting technique that involves rapidly injecting molten nonferrous alloys into dies at high pressure and speed to produce molded items. This technique has enabled industries to produce solid, reliable, durable metal products with accurate dimensions and finish.
What is Zinc Die Casting?
Zinc die casting is a manufacturing procedure that includes pouring pure molten zinc metal or any of its alloys into a die casting. The die is the shape of the product that is required to be manufactured, having all the dimensions and specifications. So when the molten zinc is poured into the die mold, it takes the shape of the die upon solidifying. As soon as the zinc solidifies, the product is removed from the die and processed further, if required, for finishing or coating.
Automated equipment designed to handle high pressure casts the zinc alloy. Because the molten metal quickly cools and solidifies when it comes into contact with the relatively cool steel side, high-pressure zinc die castings typically have better mechanical qualities than other forming techniques.
Advantages of Zinc Die Casting
Zinc die casting has an unending list of advantages extending to multiple fields of work. Due to its unique chemical and physical properties, there are a lot of zinc alloys that are used in its applications. From electrical to manufacturing applications, zinc is abundantly utilized. The following are the advantages of zinc die casting:
A lower melting temperature, higher injection pressure, and a higher cycle rate are all requirements for zinc alloys. Compared to competitive materials like aluminum, the cycle rate is 150–200% higher. One can inject zinc much more frequently than other metals as it is poured into a mold. Die-cast zinc alloys quickly become solid. As a result, more components can be made in the same amount of time while saving money.
100% of zinc can be recycled. Unlike when different plastic materials are "reground," all casting leftovers can be remelted and cast again without degrading. Aluminum needs 648.8°C to melt, whereas zinc only needs 419.5°C. Die-casting other metals requires additional heat, which increases the need for fuel during manufacturing. Zinc is more environmentally friendly than these metals since it has a lower carbon footprint.
Extended Product Life
The fact that a common zinc mold can survive ten times longer than many other molds is a significant benefit of zinc die casting. Zinc has a lower melting point and is less abrasive as a material. Aluminum tooling degradation, for example, is consequently more severe, reducing tool life and adversely compromising part quality early on. Utilizing a zinc alloy for the part could help one save a lot of money throughout the product's life cycle.
Dimensionally Accurate Products
Zinc die casting generates multi-cavity, complicated structures with tighter tolerances than many other production techniques. As a result, it produces robust, heat- and wear-resistant parts that are dimensionally consistent while maintaining incredibly tight tolerances, and huge volume runs of nearly identical parts.
The casting can serve as an electrical ground for interior circuits because of the outstanding EMI (electromagnetic interference)/RFI (radio frequency interference) shielding properties of products manufactured by the zinc die-casting method. In comparison, comparable-sized plastic parts are less durable than zinc die castings. Furthermore, the strength is derived from the alloy instead of the joining procedure since they do not include separate sections that are welded or connected.
Alloys of Zinc Available
Zinc has an excellent ability to form alloys with other metals. These alloys have unique physical and chemical properties hence becoming in demand in many electrical, medical, manufacturing, industrial, and construction applications. Given below are some of the famous alloys of zinc with a brief description:
955 Slush Alloy: It has a zinc content of 95% and about 5% aluminum. It is mostly utilized for hollow castings.
95/5 Zinc Aluminum Solder Alloy: The 95/5 zinc aluminum solder alloy, made up of 5% aluminum and 95% zinc, has exceptional adhesion and coating corrosion resistance.
Zamak™ 2 Zinc-Based Alloy: This zinc base is a frequently used alloy in rubber mold casting. It is extremely ductile and simple to cast.