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The importance of zinc die casting in the automotive industry

Zinc die casting

What is Die Casting?

Die casting is a metal casting process which is characterized by pressing molten metal into the mold cavity. The mold cavity is made using two hardened tool steel molds that are worked on during processing and work similarly to injection molds. Most die-casting is made from non-ferrous metals, especially zinc, copper, aluminum, magnesium, tin, lead, and tin-based alloys. Depending on the type of metal being thrown, a thermal or cold engine is used.

Zinc die casting

Zinc die casting

The zinc die casting process is very popular for making parts in building and industrial fields, but the most common application is in the automotive industry. In fact, cars have different parts that can be made through die casting, in such a way that the modern process of die casting was originally started for the automotive industry.

With the casting process often no further machining is needed after casting: not only is the accuracy up to 99.8%, but the casted products can also be used raw because they have a pleasant finish. The use of zinc die casting is almost 28% in the automotive industry, followed by the building and hardware sector.

Zinc has become one of the most important metals in the auto parts industry, especially for products such as door lock housing, pawl, gears and retractor pulleys in seat belt systems, but also for camshaft and sensor components. By using this metal and its alloys, it is possible to achieve strength, ductility, and flexibility that would not be possible with other materials.

In addition, zinc can be the right choice to get high-quality aesthetic components, with tight tolerances that are not possible with other materials, and to get embossing and grooves for mechanical components or gears.

Zinc Die Casting Mechanisms in Automotive

As said before, the automotive industry is the most common die casting application: using zinc and its alloys makes it possible to produce components that are able to achieve high aesthetic quality, with tight and narrow tolerance for shape morphology. Zinc alloys are also used for coatings because of its many benefits, such as improving the anti-corrosion properties of zinc which are already impressive.

Below you can find a number of possible examples of zinc plating:

  • Interior aesthetic section
  • Sunroofs Section
  • Mechanical parts
  • Engine and other underhood components
  • Power steering system
  • Parts and brake system
  • Air conditioning components and systems
  • Chassis hardware
  • Parts in the seat belt system
  • Components of climate control
  • Fuel system

Advantages for Zinc Die Casting:

  • An efficient & economical process offering various forms & forms possible.
  • High-Speed ​​Production
  • Dimension Accuracy & Stability
  • Strength & weight
  • Several finishing techniques are available
  • Simple Assembly

The Die Casting process began with the use of lead and lead alloys, magnesium and copper alloys which were quickly followed, and in the 1930s, many modern alloys still in use today are available. This process evolved from casting low-pressure injection to modern high-pressure injection of 4,500 pounds per square inch. The modern process is capable of producing high integrity, clean casting forms with excellent surface finishes.

Zinc casting alloy is a strong, durable and cost-effective engineering material. Their mechanical properties are competitive and are usually higher than cast aluminum, magnesium, bronze, plastic and most cast iron.

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Zamak 3 Die casting

Zamak 3 zinc casting

We offer ZAMAK 3 die casting for manufacturing ZAMAK 3 products. Our ZAMAK 3 products, productions capabilities, and warehousing facilities will give you quality parts at competitive prices. ZAMAK 3 is the most popular of the ZAMAK series of alloys for zinc die casting due to its castability and dimensional stability.

ZAMAK 3 Properties:

Ultimate Tensile Strength: psi x 103 (MPa)41 (283)
Yield Strength – 0.2% Offset: psi x 103 (MPa)32 (221)
Elongation: % in 2″10
Shear Strength: psi x 103 (MPa)31 (214)
Hardness: Brinell82
Impact Strength: ft-lb (J)432 (58)
Fatigue Strength Rotary Bend – 5×108 cycles: psi x 103 (MPa)6.9 (48)
Compressive Yield Strength 0.1% Offset: psi x 103 (MPa)604 (414)
Modulus of Elasticity – psi x 106 (MPa x 103)12.46 (85.5)
Poisson¡¯s Ratio0.27
Density: lb/cu in (g/cm3).24 (6.6)
Melting Range: ¡ãF (¡ãC)718-728 (381-387)
Electrical Conductivity: %IACS27
Thermal Conductivity: BTU/ft/hr/¡ãF (W/m/hr/¡ãC)65.3 (113.0
Coefficient of Thermal Expansion: 68-212¡ãF µin/in/¡ãF (100-200¡ãC µm/mm/¡ãC)15.2 (27.4)
Specific Heat: BTU/lb/¡ãF (J/kg/¡ãC).10 (419)
Pattern of Die Shrinkage: in/in.007

Zinc Die Castings Applications

Sporting Goods

– Cost-saving approaches to machined components;

– Coatings to match mating zinc parts;

– Strength for tough applications;

Zamak 3 die casting

Zamak 3 die casting

Medical

– Innovative capabilities;

– Precision designs as cast;

– For use in many difficult applications;

Switch

– Multiple cavities for cost savings;

– Multislide;

Fasteners

– Many sizes of panel nuts already tooled;

– High speed tapping capabilities;

Connector

– Four slide technology to eliminate costly secondary;

– Barrel plating for electroless nickel offers cost-effective protection and aesthetics;

– Excellent conductive alloys;

Fiber Optics

– Capable of casting complex designs;

– Close tolerance, as cast, components;

– Equipment and experience to provide small components;

Appliances

– Thin wall castings with the strength to hold up in applications;

– Surface finishes provide wear resistance ;

– Alloys designed for application specifics ;

Automotive

– Capability to incorporate multiple components into a single zinc casting ;

– Corrosion-resistant castings and platings ;

– Secondary tapping capabilities ;

– Zinc is an excellent dampening material ;

The Detail of Zamak 3 zinc casting 
Model No: Zamak 3 zinc casting
ProductName: Zamak 3 or 5 die casting
Product Origin: China
Brand Name: CNM TECH
Price Terms: FOB SZ
Payment Terms: T/T CIF L/C
Supply Ability:  300,000-400,000sets/month
Delivery Lead Time: around 30 days
If you want to purchase or know more information about Zamak 3 zinc casting,

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Zinc alloy die casting Zamak 3 Zamak 5

Zinc die casting parts

Zinc Die Casting Description :

We use four top-quality zinc alloys for our zinc die casting parts – Zamak 3, Zamak 5, ZA-8 and Zamak 2 — because they offer unique advantages for creating high-precision die castings.

Zamak 3:

As the most popular zinc alloy, Zamak 3 features exceptional ductility and impact strength. It works very well with multiple plating and finishing options,

Zamak 5:

Typically used in automotive and small engine applications, Zamak 5 exhibits excellent creep resistance, hardness, and strength.

Zamak 3 or 5 die casting parts?

For all our zinc die castings we use either Zamak-3 or Zamak-5 Zinc Alloy. Special. The Alloying is

done in our fully automatic In-house Zinc Alloying section where we manufacture all kinds of Zinc Alloys for Die Casting. Our daily Zinc Alloying capacity is 16 Metric Tonnes. Every  Alloy Heat is tested by a computerized Spectrometer for metallurgical composition.

We would be happy to quote for your requirements of low-cost high volume small precision

 Zinc Die Casting components weighing in the range of 0.25 gms to 125 gms.

We specialize in a rare combination of both – Accurate Sizes & Decorative Surface Finish

ZA-8:

Even stronger than Zamak 3 and 5, ZA-zamak8 is the ideal choice for hot chamber casting projects. It also works well with multiple plating and finishing options.

Zamak 2:

Compared to other Zamak alloys, Zamak 2 offers higher creep performance and long-term strength and hardness. It serves as an excellent bearing material and has been known to eliminate the need for bushings and wear inserts in die-casting components.

Zamak 5 die casting

Zamak 5 die casting

Zamak 3, Zamak 5, ZA-8, and Zamak 2 is well suited for the die casting process due to their ability to:

– Produce very thin walls and near net shapes

– Achieve high levels of accuracy

– Offer temperature flexibility up to 150° F

– Provide reliability with superior bearing properties

– Exhibit increased wear resistance

Please send us either your samples, drawing and other details and we will send you our quote immediately.

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