Zinc Alloy Die Casting Speaks Strength and Durability

Each metal has its own set of advantages as well as disadvantages, which are taken into consideration while deciding on the type of the die casting process for a particular product. The melting point, strength, ease of casting as well as price are the various aspects taken into consideration while creating die casting design. Zinc alloy die casting is one of the best and popularly used methods for casting.

Using zinc alloy in the casting process reaps a lot of benefits. Zinc is best known for the strength it provides. This metal does not break on bending and can also be easily be moulded into a desired shape. Zinc alloys have low melting points, and can be easily cast into the mould created based on the die casting design Plus, once hardened, zinc is extremely strong. Its tough nature makes it resistant to any major impacts. The rigidity of the metal helps in casting with low space and less weight.

Zinc possesses anti-spark quality, which means that the metal does not catch fire easily. So, it can be used in casting products that are used in high heat conditions. Another huge advantage while casting with zinc is that thin walls can be created. This property will allow you to easily produce all types of parts, with thick or thin walls. Zinc has anti-shock properties, so the tools produced using this metal have a longer life.

One of the biggest benefits of zinc alloy die casting is that you can recycle the material. If any cast has some defect, you don’t have to throw it. Simply melt it again and do the casting process again. Moreover, as you are pouring the exact amount of molten metal into the cast, there is no wastage here also. Therefore, unlike other product manufacturing processes, this technique allows you to save metal and reduce wastage at the same time. You can recycle the metal as many times as you want without any loss of properties. This aspect makes this manufacturing technique an earth-friendly process as it creates less waste and has a less hazardous impact on the environment.

In a nutshell, the above mentioned advantages make zinc a very popularly used metal in the casting process. The combined attributes of strength, resistance, low melting point and shock-proof nature make it a preferred choice for many a die casting design.

Reduce Manufacturing Costs with the Right Die Casting Design

In the die casting process, molten metal is poured into a mould that is designed in the shape of end product. The molten metal is injected at very high pressure into the mould, so it takes up the shape of the mould. This die casting process is efficient and economical as it saves time, effort and also decreases wastage at the same time. Different metals such as zinc, tin, magnesium and aluminium as well as their alloys are used in the die casting process.

There are small steps that you can take to further reduce aluminium die casting process expenses. The entire production process can be made less costly by making subtle changes in the die casting design.

Reduce the Weight

When you reduce the volume of components required for die casting, you can proportionately decrease the weight and cost of die casting. If you pour more metal into the cast, then it will take more time to set and cool, which will eat up into your production time. So, you can go for slight alterations in the die casting design like designing pockets to make thinner cross sections or use ribs to strengthen the cast product. Care should be taken while designing the location of the pockets because the wrong positioning of the pockets can affect the product’s accuracy and strength.

Parting Lines and Ejector Pins

While designing the aluminium die castings, careful consideration should be given to the parting lines and ejector pins. The parting line should preferably be straight or flat, so removal becomes easy. Ejector pins are used to remove the cast products from the mould. If the pins are neatly designed, then they will not leave any marks on the cast when it is removed from the mould. So, you finished product will not have any unnecessary marks and scratches which could then require another finishing touch.

Radii and Fillets

While creating the Die Casting Design, care should be taken to avoid sharp corners. If there are less sharp corners in the Aluminium Die Castings, the finished product will be stronger and have a cleaner finish. Also, there should not be quick ups and downs in the cross section, which will lead to erratic flow of molten metal in the cast, and finally lead to an irregular finish.

There are lots of the other techniques that can be used while designing the cast. These techniques will not only ensure product strength, but also reduce production time and decrease manufacturing costs.