Zinc Die Casting: High Precision and Excellent Properties.
Zinc is one of the most versatile die cast metals. It provides higher precision with lower tooling costs when compared to other die cast metals like aluminum or magnesium. Zinc die casting also offers a broad range of excellent physical and mechanical properties and finishing characteristics and is the easiest to cast.
Advantages of Using Zinc
One of the most significant advantages of zinc is that it reduces tooling costs. Die cast tooling is typically a considerable cost factor, so saving where possible is important. Because zinc has a low melting temperature, dies can last up to 10 times longer than those used in aluminum die casting and about five times longer than dies used for magnesium. That means fewer repairs, less downtime, and more parts produced over the tool’s life. Small zinc parts can utilize the high-speed 4-slide miniature zinc die casting process, which allows for significantly lower upfront tooling costs when compared to aluminum or magnesium. Click here to learn more about that process.
The advantages of zinc die casting include:
- Longer tool life
- Lower tooling cost (mainly if it can use the miniature zinc die casting process)
- The ability to cast near net-shaped complex geometries with thinner walls and less draft angle than castings produced with other metals reduces the need for machine features.
- Excellent balance of mechanical and physical properties, including higher yield strength and elongation when compared to aluminum or magnesium.
- Good vibration-dampening capacity compared to aluminum
- Wide range of finishing options
- Faster production time
The many advantages of zinc allow it to be used in a wide range of industries and applications.
The Zinc Die Casting Process
Zinc is cast with the fast-cycling hot chamber die casting process, which utilizes a component called a gooseneck that is submerged in a furnace filled with molten metal. Metal automatically enters the shot chamber through a hole in the gooseneck. A vertical plunger then seals the hole and drives the metal into the back of the die with high pressure. The part rapidly solidifies (within seconds), and the part is ejected from the tool.
Zinc Alloys Available at CWM
CWM casts two different zinc alloys: Zamak No. 3 and ZA-8. Both can be cast with intricate detail and close dimensional tolerances at high production rates.
Zamak 3 is the most commonly used zinc alloy in die casting because it offers superior castability and excellent finishing characteristics. Zamak #3’s elongation properties allow it to be crimped or swaged to other components.
ZA-8 is often the choice when additional strength and greater creep resistance are required.
With various machine sizes ranging up to 500 tons of locking force, CWM can produce zinc parts from miniature to over 20” long.
You can visit our request a quote page or contact Chicago White Metal to review your project with a die cast engineer.
