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What Is Zinc (zamak) Die Casting? How It Works?

Views: 17     Author: Site Editor     Publish Time: 2023-11-01      Origin: Site


Zinc/Zamak Die Casting And Working Process


The classification of die casting is typically based on the heat and pressure needed to inject molten metal into the die casting mold. However, another way to categorize the manufacturing process is by the type of material used, with Zinc (Zamak) being the most prevalent for its strength. This article explores the utilization of zinc in die casting, its working process, advantages, applications, etc.


Table of Contents of Zinc Die Casting

zinc zamak die casting parts

1. Introduction 
7. Comparison with Other Casting Methods 
2. What is Zinc Die Casting?  8. Choosing the Right Zinc Die Casting Partner 
3. How Zinc Die Casting Works 9. Quality Control in Zinc Die Casting Environmental 
4. Advantages of Zinc Die Casting  10. Considerations 
5. Applications of Zinc Die Casting  11. Conclusion 
6. Limitations of Zinc Die Casting  12. FAQs


1. Introduction of Zinc/Zamak Die Casting 

Zinc die casting is a metal casting process that is used to produce high-quality metal parts. It is a popular method for manufacturing small to medium-sized metal parts with complex shapes and tight tolerances. Zinc die casting is widely used in various industries such as automotive, electronics, appliances, and hardware. 

Zinc alloy for die casting normally have 2 types: ZAMAK 3 & ZAMAK 5

In KYLT, we keep Zamak 3, and Zamak 5 material in storage. For some special Zamak alloy, we can book it from a zinc alloy supplier as per customers' requirements. Of course, all zinc alloys have material certification. More detail Zinc/Zamak Alloy Die-casting information and services, please email us: cnkylt@aliyun.com


2. What is Zinc Die Casting?

Zinc die-casting (or Zamak die casting) is a process of melting zinc alloys (hence the name zinc alloy die-casting) and injecting them into prepared die-casting molds with high-pressure through a die-casting machine. The mold is then cooled to solidify the zinc, producing a metal part with high accuracy and excellent surface finish.

Zinc alloys are suitable for component manufacturing due to their ductility, impact strength, and low melting point. In addition, due to the low melting point of zinc alloy materials, the injection mechanism of the die-casting machine directly injects molten metal from the furnace into the mold, hence the name "hot chamber die-casting process".

In addition, compared to other materials compatible with die casting, the hot chamber process also improves the lifespan of the mold, shortens assembly time, and reduces costs.


3. How Zinc Die Casting Works?

Zinc die casting is a process that involves four main steps:


3.1. Preparation of the zinc injection mold:

The mold is made of two halves, the cavity, and the core. The cavity is the shape of the final part, and the core is used to create internal features of the part.



3.2. Zinc Injection:

Molten zinc alloy is injected into the mold at high pressure, typically between 1000 and 4500 psi.


3.3. Zinc mold cooling & Zamak alloy parts solid:


The mold is cooled to solidify the zinc.



3.4. Eject out zinc die casting parts:

The part is ejected from the mold, and the cycle starts over.


4. Advantages of Zinc Die Casting

Zinc die casting offers several advantages over other casting methods, including:

- High accuracy and repeatability

- Excellent surface finish

- High strength and hardness

- Low melting point

- Good electrical conductivity

- Good thermal conductivity

- Easy to machine and finish

- Cost-effective for high-volume production


5. Applications of Zinc Die Casting

Zinc die casting is used in various industries for manufacturing different types of parts, including:


- Automotive zinc alloy parts: 

Gears, brackets, housings, and handles


- Electronic zamak alloy parts: 


Connectors, housings, and heat sinks



- Appliance zinc die-cast parts: 

Handles, knobs, and covers


- Zamak 3 /5 hardware: 


Locks, latches, and handles



- Zinc parts for medical equipment: 

Surgical instruments and components



- Zamak components for toys and games: 

Miniature figures and game zinc alloy pieces



6. Zinc/Zamak Die Casting Parts Surface Finishes:



6.1. To Clean Burr And Flashes For Zinc Parts


6.1.1. Sanding treatment


- Sanding machine used to clean injection gate, burr, and flashes.

Video shows sanding machine used to clean burrs and flashes for zinc alloy die casting parts.


- Handheld polishing machine used to clean injection gate, burr, and flashes.

Video shows zamak lock parts flashes, injection gate and burr be polished by handheld polishing tool.


6.1.2. Punching/Stamping method treatment

Zinc die casting parts punching holes or to move-out burr and flashes by stamping method.

The punching method is used to make precision holes for zinc die-casting parts. which holes can not be made from mold directly, or holes be sealed when die-casting process mold parts or sliders are not clamped tightly.


6.2. Smooth Surface Treatment Of Zinc Parts


6.2.1. Vibration grinding / Media Tumbled for zinc die casting parts

Vibration grinding is a surface finishing process used to deburr, polish, and improve the surface quality of die casting parts.

Media Tumbling is a specific type of vibratory finishing that uses tumbling media, such as ceramic, stone, stainless steel balls, etc, to achieve the desired surface finish. The tumbling media act as both abrasive agents and assist in separating the workpieces to avoid excessive contact, preventing part-on-part damage.

The video shows Zamak die-casting parts treated by Vibration grinding with stones.




7. Assembly Services Of Zinc Die Casting Parts


Some zinc parts require assembly, then to do coating or plating treatment. We also provide assembly services as per customers' needs.

Video shows assembly a pin and punch it together zamak compass cover, then the part will be treat by powder coating.


8. Limitations of Zinc Die Casting

Zinc die casting also has some limitations, such as:

- Limited size and weight of parts

- Limited heat resistance

- Limited corrosion resistance

- Limited design flexibility compared to other casting methods


9. Comparison with Other Casting Methods

Zinc die casting can be compared with other casting methods such as sand casting, investment casting, and permanent mold casting. Each method has its advantages and limitations, and the choice of method depends on the specific requirements of the part and the production volume.


10. Choosing the Right Zinc Die Casting Partner

Choosing the right zinc die casting partner is crucial for the success of your project. You should look for a partner with experience, expertise, and a proven track record of delivering high-quality parts on time and within budget. Other factors to consider include the partner's capabilities, equipment, quality control, and environmental policies.


KYLT with over 15 years zinc die casting experience, familiar with Zamak 3, Zamak 5, Zamak 8 etc alloys die casting process. Provides zinc mold making, zinc injection, precision machining, various surface finishes to export safe packing. KYLT is your trustable "ONE-STOP" zinc die casting parts partner. Our Free quote service email: cnkylt@aliyun.com


11. Quality Control in Zinc Die Casting

Quality control is essential in zinc die casting to ensure that the parts meet the required specifications and standards. Quality checks during the entire production process, from the design phase to final inspection. These checks include:


- Zamak Alloy Material Inspection: 

Incoming zinc alloys are tested for chemical composition, purity, and quality.


- Zinc Injection Tooling Inspection: 

The molds are inspected for accuracy, surface finish, and durability.


- Zinc Die-cast Process Control: 

The injection parameters are monitored and adjusted to ensure consistent quality and performance.


- Zamak Casting Parts Dimensional Inspection: 

The parts are measured and compared to the design specifications to ensure accuracy and consistency.


- Zinc Components Surface Inspection: 

The parts are visually inspected for defects such as porosity, cracks, and surface finish.


- Zinc Parts Function Testing: 

The zamak parts may undergo functional and performance testing to ensure they meet the required standards.


12. Environmental Considerations of Zinc Die-casting

Zinc die casting is a relatively eco-friendly manufacturing method compared to other casting methods. Zinc is a recyclable material, and the scrap from the production process can be reused to make new parts. Zinc die casting also has a low energy consumption and produces minimal waste. Moreover, some zinc die casting companies implement environmental management systems to reduce their environmental impact further.


13. Conclusion

Zinc die casting is a popular manufacturing method for producing high-quality metal parts with complex shapes and tight tolerances. It offers several advantages over other casting methods, including high accuracy, excellent surface finish, and cost-effectiveness for high-volume production. Zinc die casting is used in various industries for manufacturing different types of parts, such as automotive parts, electronic parts, and appliance parts. However, zinc die casting also has some limitations, such as limited size and weight of parts and limited design flexibility. Choosing the right zinc die casting partner and implementing quality control measures are crucial for the success of your project.


KYLT provides Zamak 3, Zamak 5 die casting parts manufacturing services: zinc die casting parts molds making, Zamak parts die-cast, precision CNC milling & turning machining, polishing, painting, powder coating, electrophoretic coating, plating surface treatments etc. Free quote for you zinc alloy project: cnkylt@aliyun.com




FAQs


Q1. What materials can be used for zinc die casting?

A1. Zinc alloys are typically used for zinc die casting, such as Zamak and ZA alloys.


Q2. What is the maximum size of parts that can be produced using zinc die casting?

A2. The maximum size of parts that can be produced using zinc die casting depends on the equipment and capabilities of the zinc die casting company.


Q3. What is the typical production volume for zinc die casting?

A3. Zinc die casting is cost-effective for high-volume production, typically ranging from a few thousand to millions of parts per year.


Q4. How long does it take to produce parts using zinc die casting?

A4. The lead time for producing parts using zinc die casting depends on the complexity of the part, the equipment used, and the production volume.


Q5. Is zinc die casting environmentally friendly?

A5. Zinc die casting is relatively eco-friendly compared to other casting methods. Zinc is a recyclable material, and the scrap from the production process can be reused to make new parts. Zinc die casting also has a low energy consumption and produces minimal waste.





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