Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Zinc die casting is a manufacturing process where molten zinc or zinc-based alloys (such as Zamak alloys) are injected under high pressure into a precision steel mold (die) to produce complex, high-accuracy metal parts. The molten zinc fills the mold, cools rapidly, and solidifies, forming parts that are ejected, allowing the mold to be reused for high-volume production.

Materials: Primarily uses zinc alloys like Zamak 3, Zamak 5, or ZA-8, which combine zinc with aluminum, magnesium, and copper for enhanced properties.

Process: Involves melting zinc alloy, injecting it into a mold at pressures typically ranging from 1,500 to 25,000 psi, and cooling it to form parts with tight tolerances and smooth surfaces.

Types:

Hot-chamber die casting: Common for zinc due to its low melting point (~380–420°C), allowing faster cycles and less wear on equipment.

Cold-chamber die casting: Less common, used for alloys with higher melting points or specific requirements.

Advantages:

High Precision: Produces intricate parts with excellent dimensional accuracy and thin walls (as low as 0.5 mm).

Smooth Surface Finish: Ideal for decorative or functional plating (e.g., chrome, nickel).

Strength and Durability: Zinc alloys like Zamak 5 offer good mechanical strength and impact resistance.

Cost-Effective: Low material costs, fast cycle times, and long mold life (up to 1 million cycles) make it economical for high-volume production.

Versatility: Suitable for complex geometries, reducing the need for secondary machining.

Recyclability: Zinc alloys are highly recyclable, supporting sustainable manufacturing.

Limitations:

Weight: Zinc parts are heavier than aluminum or magnesium, limiting use in weight-sensitive applications.

Corrosion Resistance: Moderate; often requires coatings or plating for harsh environments.

Temperature Sensitivity: Zinc alloys may creep or deform under sustained loads at elevated temperatures (>100°C).

High Initial Tooling Costs: Mold design and fabrication can be expensive, making it less ideal for low-volume production.

Applications:

Zinc die casting is used across industries for parts requiring precision, strength, and aesthetic appeal, including:

Automotive: Handles, locks, carburetor bodies, and decorative trim.

Electronics: Connectors, housings, and shielding components.

Consumer Goods: Hardware (hinges, faucets), tools, and fashion accessories (buckles, zippers).

Industrial: Pump components, valve bodies, and machinery fittings.