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Zinc Pressure Die Casting and Precifine Die and Casting for High Quality Components
Zinc pressure die casting is a manufacturing process that produces highly accurate and durable metal components at high volumes. It involves forcing molten zinc alloy into hardened steel dies under high pressure. The zinc solidifies rapidly to form complex shapes with good dimensional consistency and tight tolerances. Precifine die & casting specializes in zinc pressure die casting and can produce intricate components with excellent surface finishes.
Benefits of Zinc Pressure Die Casting
There are several benefits that make zinc pressure die casting ideal for manufacturing high-quality metal parts:
- High productivity: Zinc alloy solidifies faster than other casting metals like aluminum or magnesium. This allows for shorter cycle times and higher part output. Complex parts can be mass produced efficiently.
- Dimensional accuracy: The high pressures compact the zinc into the die cavity, resulting in components that hold tight tolerances. Parts can be produced to precise specifications.
- Smooth surfaces: Zinc has excellent flow characteristics that enable it to replicate die surfaces accurately. This results in components with good surface finishes that often require no secondary machining.
- Versatile alloy options: A range of zinc alloys is available, allowing material properties like strength, ductility and corrosion resistance to be tailored as needed. This versatility supports diverse application requirements.
- Cost effectiveness: Zinc pressure die casting is a high-volume process. Significant cost benefits can be achieved through economies of scale compared to other lower-volume processes.
Zinc Alloys for Pressure Die Casting
The most common zinc alloys used for die casting include Zamak alloys 3, 5 and 7. These contain alloying elements like aluminum, magnesium and copper that enhance properties like:
- Strength: Zamak 3 offers high yield strength while 5 and 7 offer even greater tensile and yield strengths. This allows production of sturdier components.
- Ductility: Zamak 3 has good elongation properties for flexible, damage-resistant parts. Zamak 5 and 7 are also reasonably ductile.
- Wear resistance: The copper content in Zamak 5 and 7 improves wear characteristics, for components with sliding contact surfaces.
- Corrosion resistance: Aluminum and magnesium in the alloys provide good resistance to corrosion, especially in Zamak 5. This expands potential applications.
The percentage of alloying elements can be varied to tweak the alloy properties as per the application needs. Precifine die & casting experts select the optimal zinc alloy for each component design.
The Zinc Pressure Die Casting Process
Zinc pressure die casting involves the following key steps:
1. Tooling - Steel tooling is fabricated comprising of two die halves that contain the component form/features when closed. The dies are hardened to withstand the high pressures involved.
2. Melting - Zinc ingots are melted in electrically heated furnaces until the alloy liquefies. Precise control of temperature is critical for optimum fluidity.
3. Injection - The molten zinc is forced into the die cavity at high velocities and pressures of around 10-45 MPa via a hydraulically actuated plunger.
4. Solidification - The zinc rapidly cools and solidifies into the precise shape of the die cavity, aided by water cooling channels in the die.
5. Ejection - Once fully solid, the die halves separate and ejector pins push the cast component out of the die. Robotic handling often transports parts to trim machines.
6. Finishing - Trimmed components may undergo grinding or polishing, plating, painting or other secondary finishing processes.
Precifine Capabilities in Zinc Pressure Die Casting
Precifine die & casting is an industry leader in zinc pressure die casting. With advanced production facilities, our capabilities include:
- Tooling design and fabrication with precision CNC machining for complex die cavities. We use P20 steel for durability under high pressure.
- Multi-slide cold chamber die casting machines capable of clamping forces over 4500 kN. High injection speeds ensure complete die fills.
- In-house zinc alloy melting with computerized temperature control for consistent molten metal quality. We recycle and recover zinc for efficiency.
- Stringent process monitoring leveraging sensors, testing equipment and statistical control methods to ensure repeatable high quality.
- Secondary processes like trim die fabrication, CNC machining, vibratory finishing, chrome plating, powder coating and silk screening.
- Experienced engineers and toolmakers that collaborate with customers to optimize designs for casting and minimize secondary machining requirements.
We routinely achieve tolerances of +/- 0.1% on critical dimensions while maintaining surface finishes around Ra 1.25 μm (50 μin) directly out of the die. Highly complex geometries with delicate features, threads and inserts can be reliably produced. Our wide zinc alloy expertise enables us to deliver the needed part functionality.
Applications of Zinc Pressure Die Cast Components
Given their beneficial properties, zinc pressure die cast parts find application in diverse industries including:
- Automotive: Lock hardware, door handles, pivot brackets, clutch parts, steering components
- Consumer hardware: Furniture fittings, wire connectors, hinges, fasteners, locks, tool parts
- Electronics: Shields, covers, frames, battery casings, switch contacts, circuit breakers
- Medical: MRI scanners, surgical tables, medical carts, equipment housing
- Industrial machinery: Gears, levers, couplings, motor mounts, fittings, brackets
Precifine has experience producing millions of zinc die cast components across these industries while meeting exacting customer specifications. We implement robust quality systems and are ISO 9001 certified. Our customers can rely on consistent, defect-free delivery of their high-volume zinc cast parts.
Partnering with a Zinc Die Casting Expert
The properties of zinc alloys combined with die casting’s design flexibility provide extensive possibilities for component innovation. However, realizing these benefits requires an experienced partner. Precifine die & casting has a 50-year track record of providing excellence in zinc pressure die casting services. Our expertise and capabilities enable us to deliver high-quality, cost-effective solutions tailored to your application needs.
To discuss how zinc die casting can add value to your products, contact Precifine today! Our engineering team is ready to partner with you through the design, tooling fabrication, production ramp-up and assembly stages to ensure your program’s success. CNC Milling CNC Machining