Zinc Alloy Die Casting
What is Zinc Die Casting?
Zinc die casting is used to produce a wide range of parts and components within numerous industrial applications. The mechanical properties of zinc alloy die castings at average temperatures are superior to sand castings of grey iron, brass, and aluminum, particularly toughness and impact strength. They are much stronger, tougher, and more dimensionally stable than injection molded plastics. The reduced cost and improved properties have made it an ideal replacement for iron, copper, aluminum alloys or plastics parts.
What is Zinc Die Casting Used For?
Zinc alloy die casting services from SKS are commonly used to manufacture high-quality parts and components throughout the aerospace, aviation, and medical industries. We utilize the most technologically advanced die casting and machining equipment available, together with complete in-house design/engineering and tool/die operations, to provide zinc die casting to your exact specifications.
Contact us for more information regarding our precision zinc die casting service options, or call us at 510-523-2541, and we’ll gladly assist you. SKS is your trusted source for zinc alloy die casting services.
What Are the Advantages of Zinc Die Casting?
Zinc die castings provide improved strength, toughness, firmness, performance and cost-effective efficiency compared to other alloys. The zinc alloy die casting properties often exceed the ones of other alloys such as aluminum alloys, magnesium, bronze, plastics and other cast irons. Some of the benefits associated with zinc die casting include:
- Improved Castability
- Shortened Cycle Time
- Extended Die
- Ideal Mechanical Qualities
What Zinc Alloys Are Used in Die Casting?
At SKS, we can diecast zinc Zamak #2, #3, #5, #7, ZA8 and ZA27. Zamak is characterized by excellent retention of impact strength and long-term dimensional stability. It has been used for decades in many engineering applications, delivering excellent performance results. Zamak zinc alloy die casting material options include:
- Zamak 2 - Often referred to as Kirksite, this zinc alloy is the only Zamak used for gravity casting. It also provides the highest strength and hardness of all Zamak alloys. Zamak 2 is also a good bearing material and may eliminate bushings and wear inserts in die cast designs.
- Zamak 3 - This zinc alloy is often the first choice when zinc die casting is considered. Zamak 3 maintains an excellent balance of desirable physical and mechanical properties, superb castability and long-term dimensional stability.
- Zamak 5 - Zamak 5 provides increased strength and hardness over Zamak 3. It is the most widely used zinc alloy in Europe.
- Zamak 7 - This high-purity alloy contains lower magnesium content while maintaining tighter impurity specifications. This results in improved casting fluidity, ductility, and surface finish.
- ZA8 - ZA-8, or zinc-aluminum alloy, contains significantly more aluminum than the Zamak group of alloys. ZA-8 contains approximately 8.4% aluminum and is the only ZA alloy that can be hot-chamber die-cast, an important consideration when selecting a material for a component.
- ZA27 - ZA-27, or zinc-aluminum alloy, contains significantly more aluminum than the Zamak group of alloys. The number 27 represents the approximate percentage of aluminum.
What is Zinc Die Casting Used For?
Due to its unique cost and time-saving properties, zinc die casting is commonly utilized in several industries for numerous applications. Some of the industries that regularly use parts and components manufactured through the zinc alloy die casting process include:
- Appliance manufacturers
- Mechanical design
Custom Zinc Die Casting Example
- Component description: Home security lockbox
- Original component raw material: steel tubing
- Manufacturing processes: bending, welding, machining, painting. The original manufacturing process is virtually a custom-made-to-fit component.
- Die casting component raw material: zinc alloy die casting - The die casting process virtually eliminates the variability of the component's critical and functional features. The reduction in cost and lead time is dramatic.
Cost Reduction is over 50%.
What Are The Zinc Die Casting Processes?
Zinc can utilize both hot and cold chamber casting processes. Within the zinc hot chamber die casting process, the injection mechanism of a hot chamber machine is immersed in a molten metal bath within a metal holding furnace. The furnace is attached to the machine by a metal feeding system called the gooseneck. Four or five shot outputs per minute can be produced through the zinc hot chamber die casting process.
The cold chamber die casting process is opposite that of the hot chamber method. Casting molten metal is poured into the cold chamber or cylindrical sleeve by ladle within cold chamber die. A hydraulically-operated plunger seals the cold chamber port and forces the metal into the die cavity at high pressure.
Assembly & Installation Services
For projects with specific assembly and installation needs, SKS Die Casting works closely with customers to explore assembly and installation solutions. SKS can help with such requests as:
- Cast into the components drawing specified pins.
- Implement machined external threads on casting bosses.
- Cast holes to the dimension of drill size for internal threads.
- Install pins and/or helicoil inserts after machining.