Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Zinc die casting is a specific type of die casting that uses zinc alloys as the primary material to create precise, durable, and complex metal parts. It follows the general die casting process but leverages the unique properties of zinc, making it ideal for certain applications. 

1.Zinc Die Casting Process

Zinc die casting follows the standard die casting process, typically using the hot chamber method due to zinc’s low melting point:

Mold Preparation: A reusable steel die, designed to match the part’s shape, is lubricated and closed.

Melting and Injection: Zinc alloy is melted in a furnace (melting point ~380–420°C or 720–790°F). In a hot chamber machine, the molten zinc is held in a furnace connected to the die, and a plunger injects it under high pressure (1,000–30,000 psi) into the die cavity.

Cooling and Solidification: The molten zinc cools and solidifies rapidly (within seconds) due to its low melting point and the cooled die.

Ejection: The die opens, and the solidified part is ejected using ejector pins.

Finishing: Excess material (flash) is trimmed, and parts may undergo secondary processes like machining, plating, or coating.

2.Key Characteristics of Zinc Die Casting

Material: Uses zinc alloys (e.g., Zamak 3, Zamak 5, ZA-8), known for strength, ductility, and low melting points.

Precision: Achieves tight tolerances (±0.05–0.1 mm) and complex geometries with thin walls (as thin as 0.5 mm).

Surface Finish: Produces smooth surfaces, often requiring minimal post-processing or allowing for high-quality plating (e.g., chrome, nickel).

Production Speed: Fast cycle times (seconds) due to zinc’s low melting point and hot chamber process, ideal for high-volume production.

3.Advantages of Zinc Die Casting

High Strength and Durability: Zinc alloys offer excellent mechanical properties, including high impact resistance and hardness.

Cost-Effective: Lower melting point reduces energy costs, and longer die life (up to 1 million cycles) lowers tooling costs compared to aluminum or magnesium die casting.

Complex Shapes: Enables intricate designs with thin walls and fine details.

Versatile Finishing: Zinc parts can be easily plated, painted, or powder-coated for aesthetic or functional purposes.

Recyclability: Zinc is highly recyclable, supporting sustainable manufacturing.

4.Limitations

Material Limitation: Restricted to zinc alloys, less suitable for high-temperature applications (zinc softens above 150°C).

Weight: Zinc is denser than aluminum or magnesium, making parts heavier.

Not Ideal for Large Parts: Best suited for small- to medium-sized components due to die size and cost constraints.