Die casting is a very common metal casting process that involves forcing molten metal into a mold cavity under high pressure conditions. Two hardened tool steel die casts are used to create the mold cavity. These are machined into the shape required, and work just like an injection mold. Usually, non-ferrous materials like copper, zinc, magnesium, aluminum, lead, pewter, and tin based alloys are used for creating the die casting. Either hot or cold chamber machine is used, depending on the type of material that is being cast. Zinc die casting is a popular die casting process that employs zinc metal.
Die casting is very commonly used because of the advantages of the process:
· Exceptional dimensional accuracy can be obtained, which is typically mm for the first cm and mm for every additional centimeter
· Really smooth cast surfaces can be obtained
· It is possible to cast really thinner walls as compared to the sand and permanent mold casting
· Secondary machining operations are not required
· Production rates are really high
· Inserts like heating elements, threaded inserts and high strength bearing surfaces can be cast in
· High tensile strengths of about mega Pascals can be achieved for the casts
· Low fluidity metals can be cast
The only disadvantage of the die casting technique is the high capital cost involved. But, the advantages outweigh this one disadvantage of the process. Among the different die casting processes, zinc alloy die casting is one of the most common.
Zinc is a very common metal that is easily available and used. The main reason for opting for zinc die casting is that these castings are safe, secure, convenient, and also act as a decoration. Their physical characteristics and mechanical properties make it a perfect option for all requirements.
Zinc alloy die casting is well known for the hardness and strength. It is an ideal metal that can be used in place of other stamped, pressed, machined, and fabricated items. Zinc alloys are known to have the following characteristics that make it an ideal metal for the die casting process:
· Very hard
· High strength
· High thermal conductivity
· High stability
· Dimensional accuracy is high
· The raw material is of low cost and affordable
· Joining is eased by the ability to cold form
· Thin wall capability is high
· Finishing characteristics are of high quality
· Resistance to corrosion is just outstanding
· Full recyclability can be achieved
So, now that you see why most companies prefer to use zinc and zinc alloys for die casting and other manufacturing purposes, you can even start using the process for your machinery and equipments.