Advantages of Die Casting Zinc Alloys

Advantages of Die Casting Zinc Alloys. Die casting is a process that has quickly earned worldwide preference in the industrial community over the last few decades. The process has proved itself to be more efficient, economical, and quality-oriented as opposed to other casting processes out there. This is why there are now more die cast parts being sold than any other cast parts. One of the most important things to consider in the die casting process is the material to be used. In this aspect, zinc alloys are certainly some of the most popular choices. Die casting zinc alloys provide manufacturers and their customers alike with various advantages, which this article will briefly point out.

First of all, die casting zinc alloys are not as expensive as other alloys available. In fact, they are the cheapest materials as far as production (and post-production) costs in the die casting process are concerned. This is because they zinc alloys have excellent finishing properties that make them ready for selling even without undergoing polishing from tooling machines. Part consolidation eliminates further operations. Zinc is also the easiest alloy to cast. Zinc alloys all have high impact strength and ductility. They give consistent quality even when created in large volumes, resulting in the long life of the die molds used and the cost-effectiveness of all production stages. Die casting zinc alloys also require only minimal draft angles on their internal features so that their collective unit price is lower, bringing much financial convenience to both the manufacturers and the consumers.

Die Casting Blog gives information on how to get a zinc die casting part for manufacturers. If you are looking for Die Casting Zinc Alloys or if you need ZA Die Casting Alloys will give you more information you can use for manufacturing.

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Zinc Die Casting Machine and How They Work

Zinc Die Casting Machine and How They Work. Die casting machines are of two basic types. One is the zinc hot chamber machines. This is also called the “gooseneck machines.” The other type is the cold chamber machines.

To feed the die, the zinc hot chamber die casting machines depend upon a pool of molten metal. At the start of cycle, the machine’s piston is drawn back and this gives way for the molten metal to fill the “goose neck.” Piston then forces zinc metal out of the gooseneck and sent to the die. This system has a fast cycling time and melting the metal in the casting machine is convenient. However, in this system, high-melting point metals cannot be utilized. Also aluminum cannot be used. Aluminum picks up iron. For this reason, hot chamber machines utilize zinc, tin and lead based alloys.

When the die casting alloy cannot be used in zinc hot chamber die casting machines, then the cold chamber machines are used instead. Among these alloys are magnesium, aluminum, copper and zinc alloys with a big composition of aluminum. The cold chamber system has a shower cycle time. This is due to the need to transfer molten metal from the furnace to the cold chamber machine.

Since cast irons cannot withstand high pressures, the dies and zinc die casting tools used in die casting are often made out of hardened tool steels. This makes dies very costly, and consequently high start up costs. There are also cores involved to cast features such as undercuts. Since they disintegrate due to high pressures, sand cores cannot be used in zinc die casting and die casting tooling. Metal cores are used instead. Wear and erosion limit a die’s life. This is strongly dependent on the molten zinc metal’s temperature.

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Zinc Parts Die Casting Process

Zinc Parts Die Casting Process. The process of die-casting is a common forming process for most metals. This is a casting method, which employs the use of dies for molding to be done. The casting method is employed when no other practical means of forming the metal is applicable. This is denoted when any of the following conditions are observed: when the desired product or shape is too large for other practical processes; when properties such as strength and quality are not very important considerations; and when the alloying metal incorporated has very low ductility making hot working or cold working hard to employ.

For practical and economical reasons, the zinc die casting process is considered in most industrial applications, specifically in the automobile industry, where zinc is widely used. In the zinc die casting process, the zinc metal is prepared for melting inside the furnace, where the melting temperature is achieved. The zinc has to be melted in such a way that it assumes the liquid state. The molten metal is then poured at a high velocity into a set of metal dies, which are maintained at a certain pressure. The metal is then allowed to cool until it completely solidifies within the die. When complete solidification is ensured, the dies are opened, and the molded zinc metal casting is removed.

The zinc die casting process is proven to be cost effective and economical over the other forming processes of metals, most especially when it requires the molding of large parts, and when strength is not of utmost consideration.

Zinc Die Casting Blog gives information on how to get a zinc die casting part for manufacturers. If you are looking for Zinc Die Casting Part Prices or if you need a mold, look at Zinc Die Casting Tooling will give you more information you can use for manufacturing.

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Miniature Zinc Die Castings

Advances in technology have brought about great demands from the industry, most especially in design, manufacturing, and fabrication. These demands include intricate and precision parts for electronics, medical, automotive, general hardware, and communications. Due to the increase in these demands, there is also an increase in the demand for precision die casting parts. These are more popularly known as, miniature zinc die castings.

These are basically precision molded parts that are used for various applications. The most popular die casting method is zinc die casting. It is a less expensive and more cost effective casting method. In the production of precision parts, the multi-side die casting method is typically observed.

The casting of miniature zinc parts is a tedious process, as there are certain factors, like weight, that has to be considered. The weight of a miniature zinc die castings can be as low as a fraction of an ounce, thus making the process complex and delicate. Although the process of miniature zinc die castings is just almost the same as the hot chamber die casting for the larger parts, machines that are designed to produce these intricate parts are more efficient and are faster.

Some examples of miniature zinc die castings are those that are supplied for automotive parts, medical parts, military parts, sports and recreations parts, and even aerospace parts. There are countless applications for precision parts so much so that there are also a lot of companies that are fabricating the machines for these die castings. These companies offer standard and custom made miniature zinc die castings kits that would cater to the complexity and delicacy of the process.

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The Process of Hot Chamber Zinc Castings

The Process of Hot Chamber Zinc Castings

In the hot chamber zinc die casting process, slabs of zinc are liquefied inside a furnace with a temperature of approximately 700-800 degrees Fahrenheit. When melted, the zinc metal stays in the furnace. The gooseneck or shot sleeve is immersed in the hot chamber and the molten zinc is injected into the two die halves being held together by the machine. The two halves of the die casting molds are mounted on the die casting machine and the machine shuts off and clamps the two die halves together. The molten zinc metal is under high pressure until such time that the metal solidifies (approximately less than a minute). Die halves then open up and the part or parts are ejected and taken out either manually or automatically. Finishing works include trimming, tumble deburring, precision machining, painting, anodizing, chrome plating and assembly.

Hot chamber zinc die casting machines are used mainly for zinc, lead, magnesium, copper and other low melting point alloys that do not easily erode metal furnace pots, plungers and cylinders. The injection mechanism of a hot chamber zinc casting machine is soaked in the molten metal bath of a metal holding furnace. The furnace is connected to the machine by a metal feed system called gooseneck or shot sleeve. As the injection cylinder plunger goes up, a port in the cylinder opens, permitting hot molten metal to enter into the cylinder. As the plunger moves downward, it shuts the port and forces molten hot metal into the gooseneck and nozzle into the die cavity. When the metal has already solidified in the die cavity, the plunger is removed, the die opens and the casting is ejected.

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