Uniformity Dwells in Die Casting Design

Any tool manufacturing company, be it an automobile, gadget or toy making companies are involved in mass production for which uniformity is of prime importance. With respect to size, shape, structure, calibration, etc., one can hardly find any difference. The basic concept behind this uniformity is a die that is used for manufacturing. Every product is designed with high accuracy and with finished surface with the help of die casting. The use of die casting is cost effective as it nearly eliminates the need of refinishing or scraping any part. The assembly line is reduced, resulting in cost efficiency and reduction in assembly time. All this can be made possible with the use of suitable die casting design.

Let us basically focus on the concept of die casting. The furnace is used for die casting in which the metal is melted. And this molten metal is forced under pressure into a cavity of mold. This mold is made with the use of two steel dies which are hardened. These molds are shaped into the required die casting design. These dies are designed in such a way that it can produce any required shape, be it complex or the simplest. But the outcome is accurate and uniform. Though the process to make parts with the use of die casting is simple the metal dies and casting machines involve huge capital cost. Thus, there is a need of mass production.

Non-ferrous metals or alloys of metals like zinc, aluminum, copper, magnesium, tin or lead are used to make the die casting. The process of die casting involves two types of machines viz. hot chamber machine and cold chamber machine. Hot chamber machines are used for alloys having a low melting point like zinc, lead and tin, whereas cold chamber machines are used for alloys like aluminum, copper and magnesium that has a high melting point. Once the molten metal gets injected into these molds, it cools down and attains solid state on these machines which is known as the casting. The process of direct injection is used for making zinc alloy die casting so as to get fine surface and better finishing. The plating zinc alloy is essential as it can undergo corrosion when exposed to salt water. Hence, it has to be coated in order to maintain its luster.  

Instead of brass or iron cast, zinc alloys are always preferred, though its tensile strength is lower. Its melting point is around 800 degree Fahrenheit.  Zinc alloy die casting is highly beneficial as it has a low melting point and die casting using zinc alloy is easy to fabricate as it is highly ductile. It can be coated with ease and the final outcome is flawless and can retain its luster for longer period.  

Why Zinc Alloy Die Casting Becomes the Prime Choice for Manufacturers?

The use of metals in industries has been vast and almost every manufacturing industry uses different kinds of metals. There are a number of processes by which metals are processed into different forms. Die casting is one of the popular manufacturing processes. It is preferred above all other kinds of processes due to the quality of the finished goods and also the ease of manufacture. Zinc alloy die casting is preferred by most of the manufacturing industries.

Zinc is a widely used and easily available metal. Zinc die casting applications are widespread and are all around us everywhere. Zinc alloy die casting is used for numerous decoration and functional applications.

Key Advantages of Zinc alloy die casting:

There are many benefits of using Zinc alloy over others.

• Thinner wall sections can be achieved compared to other metals due to high casting fluidity.
• High production rates can be achieved.
• The number of secondary machining operations is very little or none at all.
• The surfaces of the finished products can be made really smooth.
• It is very easy to cast in inserts like threaded inserts, heating elements, and high strength bearing surfaces.
• It is possible to cast low fluidity metals.
• Very high dimensional accuracy can be obtained.
• The casts are able to achieve high tensile strengths as well.

This process requires a good amount of capital investment. This is known to be the only disadvantage of the process.

Zinc alloys are commonly used by a die casting manufacturer since they have the following properties to make them ideal for the process:

• They are very strong
• They are stable
• They have high dimensional accuracy
• The raw material is affordable and low in cost
• They are very high
• They have high thermal conductivity
• High quality finishing characteristics are available.
• Highly resistant to corrosion.
• You can achieve full recyclability.
• The ability to cold form makes joining easier.
• They have high thin wall capability

Zinc alloys are far better to use than any other machined, pressed, stamped, and fabricated items. They are well known for their hardness and strength. These castings are safe, convenient to manufacture and use, secure, and can even act as part of a decoration. You just need a good die casting manufacturer who is able to provide you good quality items. This is most important. You need to do enough research to find one such manufacturer who has the reputation of being trustworthy and delivers on time.