24 May Charicteristics of Zinc Die Casting Process
Most of us may get confused over zinc and aluminum casting. but actually there are few difference between zinc die casting and aluminum die casting. If you have decided to consider Aluminum die casting, then there must be plenty of reasons you have chosen Zinc over Aluminum. It is a known fact that Zinc is a hard metal but you need to know that apart from Zinc being dimensionally stable, it has high modulus and self-lubricating characteristics. The metal parts made from other reinforced polymers are far less durable than those made from Zinc. Better mechanical properties and superior finishing make Zinc alloys the first choice in tool manufacturing industry.
As compared to Aluminum Die Castings, the tooling life of Zinc is at least ten times longer. Since the casting temperature for Zinc is low, the thermal shocks they create are minimum which enhances the tool’s life. Since the manufacturing cost of die is always on the higher side, a die made from long lasting zinc alloy will save a lot in the long run.
Superior thermal and electrical conductivity
Zinc is better conductor of heat as well as electricity than aluminum. Zinc for that reason is used in the manufacturing of most of the electrical components and heat sinks.
Aluminum has a high melting point and hence needs cold chamber for casting process which consumes higher cost and time. Zinc, on the other hand, has low melting point and thus saves energy, time and cost at the same time. In the case of Zinc, “Hot Chamber” is used for casting which is cost-effective.
Faster Cycle times
The hot chamber casting process used by Zinc is much faster and automatic operation as compared to Cold Chamber technology used by Aluminum. The aluminum is poured manually to the die whereas Zinc in the hot chamber is pushed through die by an automatic plunger. The faster production cycle saves a lot on the pocket.
Higher casting fluidity
With Zinc, you can cast a much thinner, lighter and compact product due to its high fluidity property. You can cast the walls as thin as 0.25 inches with Zinc that lets you create stronger and cost effective tools.
Zinc die casting involves very precise tolerance level as compared to Aluminum. This is one of the major advantages of zinc casting and hence does not require any additional machining. Zinc die casting is rightly called the Zero machining casting and it also eliminates the extra manufacturing costs.
Zinc undoubtedly has a better finish than aluminum since aluminum can be subjected to higher temperatures and it develops some unevenness on the surface. Zinc die casts can easily be plated, painted, anodized, chromed or polished. Due to elegant finish, Zinc casting is used in making home decor pieces.
The consumers today not only demand durability and functionality but also stress greatly on aesthetics of what they are getting for their home. From high-end sophisticated products to daily use goods, Zinc die castings are now the market leaders in manufacturing quality products with their high precision and longer life.