Many engineers like to design products in zinc alloy thanks to the many benefits of engineering in zinc. Compared to other metals used in die casting, zinc tends to produce with relatively precise dimensions. Casting with zinc alloy also allows for longer tool life compared to other common materials, such as aluminum. When casting in zinc, the finished product tends to be strong and provide great impact strength and creep resistance.
Key Advantages of Engineering in Zinc
Long Tool Life
When manufacturers think about diecasting, they often think of aluminum instead of zinc. This is usually because aluminum is lighter than zinc, which makes identical products appear cheaper to produce in aluminum.
However, Zinc is much kinder to the tool compared to aluminum, allowing for much longer tool life and lower tooling costs over the life of the product.
The primary reason for the improved tool life and reduced tool cost is due to the lower melting temperature of zinc compared to aluminum. With zinc you have less heat checking, therefore you have less die erosion and soldering effects. As a result, tools can last much
At Deco we have seen many castings last for well over one million shots on the tool.
While tool life depends on the geometry and complexity of the part design, zinc tools tend to last significantly longer than aluminum tools, in some cases up to 5 times longer.
Quick Solidification
Generally speaking, the quicker a part is produced, the less expensive the process becomes. Zinc rapidly solidifies during the die casting process, resulting in an exceptionally brief cycle time for part production.
Operations are also faster with zinc’s lower melting points.
When engineering in zinc components, you typically can produce more parts per hour compared to most other die castings.
The quick solidification means that the die must be cooled to prevent it from overheating. To obtain a good high-quality part, operators utilize these lines to maintain the die at the proper temperature. Design engineers plan water lines or oil lines have the ability to run through the die.
Impact Strength
Impact strength is one of the areas where zinc performs the best. Zinc is more than double the strength of aluminum for impact strength. This impact strength can be improved further with the selection of specialty alloys. You can learn more about zinc alloy types and their properties here.
High Thermal Conductivity
Zinc’s high thermal conductivity enables precise and accurate finishing of parts. Its excellent thermal and electrical conductivity also make it ideal for engineering components in electronic devices or for heat dissipation.
Zinc alloy is commonly used by engineers designing connectors, switches, sensors, and heat sinks because of this useful property.
Precision Engineering in Zinc
When a hot metal cools, it typically undergoes some amount of shrinking during the cooling process. This “heat shrink” tends to be relatively minimal in zinc alloy compared to other materials.
Thanks to this property of zinc alloy, it tends to be easier to hold tighter tolerances in the final casting.
Zinc’s low melting point also allow the parts to cool relatively quickly, reducing the risk of warping or distortion during the cooling process.
Zinc alloy also has a property of high fluidity, meaning it flows into the tool cavity well when melted without excessive pressure. This fluidity allows for better manufacturing of complex shapes and fine details.
Contact our Experts
Deco Products has been designing, operating, and maintaining zinc die-cast tooling since our founding in 1960. We invite you to contact us with your next product design to benefit from our expertise in designing and producing zinc castings.
Contact our Experts
Michele Duwe
Michele Duwe is the Sales and Marketing Manager with Deco Products. She has eight plus years as a digital marketing manager and over a decade of sales and marketing experience.
