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Zinc Pressure Die Casting - An Efficient Manufacturing Process for Complex Parts

Zinc pressure die casting, also known as hot chamber die casting, is a manufacturing process used to produce complex metal parts at high volumes. In this process, molten zinc alloy is injected under high pressure into reusable steel molds, called dies. The zinc solidifies rapidly inside the die, taking its shape. This allows for the economical production of intricate, high-tolerance metal components with excellent dimensional stability.

Compared to other casting methods, zinc pressure die casting offers several advantages:

- High production rates: Parts can be produced quickly, around 15-20 cycles per hour per die. This makes it ideal for mass production.

- Excellent dimensional accuracy: Tolerances up to ±0.005 inches are possible, reducing the need for secondary machining.

- Complex geometries: Intricate shapes, even with hollow or thin-wall sections, can be cast easily.

- Superior mechanical properties: The rapid cooling results in a fine-grained structure, providing greater strength.

- Wide range of alloys: Zinc alloys like Zamak 3, Zamak 5, ZA-8 and ZA-12 are commonly used. Their properties can be tailored as per the application.

- Lower costs: Combining high production rates, low material costs and minimal secondary processing results in very low component costs.

The Process of Zinc Pressure Die Casting

The various steps involved in zinc pressure die casting include:

1. Design and Die Manufacturing - Dies are made from tool steel or hardened steel alloys and are machined to form the desired part shape. Proper design is crucial for producing castings with minimal defects.

2. Melting and Alloying - Zinc ingots are melted in a furnace and specific alloying elements like aluminum, copper or magnesium are added to obtain the required chemical composition.

3. Die Lubrication - The dies are sprayed with lubricants to facilitate easy ejection of the castings. Water-based lubricants are common.

4. Filling the Die - The molten zinc (around 385-450°C) is injected into the die under high pressures of 10-25 MPa. This facilitates filling of thin sections and complex shapes.

5. Solidification and Cooling - The molten zinc rapidly solidifies as the dies cool the material to around 150°C in 10-30 seconds. This results in fine-grained castings.

6. Ejection - After solidification is complete, the die opens and the casting is ejected using guide pins and ejector pins. The casting is then removed from the pins and trimmed of overflows.

7. Finishing - Any additional finishing operations like surface treatments, drilling, tapping or polishing are done to obtain the final component. The dies are sprayed again and the cycle repeats.

Advantages of Zinc Pressure Die Casting

The major advantages of zinc pressure die casting are:

- Excellent dimensional accuracy and stability. Parts require minimal secondary machining.

- Thin walls and complex geometries are possible. Intricate shapes can be mass produced.

- Mechanical properties like tensile strength, ductility and impact strength are superior compared to other casting processes.

- Multiple parts can be combined into one casting, lowering assembly costs. Mating surfaces can also be cast, reducing tolerances.

- Automation is easy, enabling high production rates of 10,000-50,000 pieces per week. This results in low component costs.

- Zinc alloys offer excellent corrosion resistance, decorative finishes, and are recyclable.

- Secondary plating and finishing is easier compared to other casting processes.

- Lower melting point of zinc alloys (385-450°C) reduces die wear and enables faster cycling.

- Significantly cheaper compared to die casting processes like aluminum or magnesium.

Common Applications of Zinc Pressure Die Cast Parts

The favorable economics and material properties have resulted in zinc die casting becoming an indispensable manufacturing process. Typical applications include:

- Automotive: door handles, locks, hinges, windshield wiper components, lighting fixtures.

- Consumer goods: zippers, toys, decorative furniture hardware, power tool housings.

- Electronics: EMI/RFI shielding, semiconductor casings, switchgear, cable connectors.

- Medical: dental implants, orthopedic devices, surgical equipment.

- Military and aerospace: communication equipment, missile and antenna components.

Precifine - Leading Manufacturer of Zinc Pressure Die Cast Parts

Precifine is a distinguished manufacturer of zinc pressure die cast parts and related zinc alloy castings. With over 15 years of experience, Precifine provides end-to-end solutions from design to delivery of finished components. Their manufacturing capabilities include:

- State-of-the-art machining centers with automated production lines. Highly accurate and precise tooling.

- In-house zinc alloy melting and casting facility using fully automated hot chamber die casting machines. Options for robotic swapping of dies to enable high-mix production.

- Stringent process controls to meet zero-defect quality standards. Real-time monitoring at each stage.

- Vast alloy development expertise. Capability to customize alloy compositions to achieve required mechanical, thermal or environmental performance.

- Wide range of secondary finishing processes like CNC machining, drilling, tapping, painting, powder coating, electroplating, laser etching etc.

- R&D team to collaborate with customers for design optimization and manufacturability. Simulation techniques like fluid flow and thermal modeling are utilized.

- Support for low to high volume production. Capable of supplying from hundreds to millions of components.

Precifine provides die cast parts to customers globally, serving various industries like automotive, consumer appliances, electronics, and aerospace. With their state-of-the-art facility, stringent quality control and customer-focused approach, they offer exceptional value in zinc die casting and related precision zinc alloy components.


Zinc pressure die casting is an efficient high-volume manufacturing process capable of producing complex, high-precision components at low costs. The favorable properties of zinc alloys combined with the benefits of permanent mold casting result in stable, net-shape parts with minimal secondary processing. Precifine utilizes the latest technologies and automation to provide top-quality zinc die cast components tailored to customer requirements. Their expertise in this field makes them an ideal partner for developing and manufacturing precision zinc alloy die cast parts. CNC Milling CNC Machining