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.