The Advantages of Zinc Die Casting
Choosing the right material and process for your parts is of utmost importance to you. Your selection will impact the products that you provide to your customers and ultimately their satisfaction. Selecting the wrong material or the wrong process could spell disaster for you!
With a variety of zinc alloys to choose from, combined with the casting process, zinc die casting is worth your consideration. And with Deco Products’ expertise of almost 6 decades of experience, we can assist you in not only evaluating the mechanical, physical and chemical properties of each alloy, but also the process in which they are manufactured so that you get what you need to best serve your customers.
Advances in technology have allowed us to provide innovative, lighter weight, longer lasting, and more cost-effective products in several key areas. These benefits often exceed those of cast aluminum, plastics, bronze, and most cast irons.
Thinner Walls, Stronger Parts
Zinc alloys are stronger than other materials, such as plastics or aluminum. This means zinc castings may be produced with thinner walls and less material to optimize strength in ways other materials cannot. For example, although aluminum’s cost per pound may “appear” less, its castings may require more material and cost for the same strength.
Zinc alloys, with lower melting temperatures and higher-pressure injection, have a 150-200% higher cycle-rate than other competing materials, such as aluminum. Where aluminum is ladled into a mold, we are able to inject zinc at much higher rates. This, along with more rapid zinc solidification, allows us to produce more parts in the same amount of time and pass along cost savings to our customers.
Tighter Tolerances, Less Machining
Zinc alloys allow us to produce parts with tighter tolerances than aluminum or plastic. Zinc’s fluidity provides increased precision compared to other materials allowing designs that do not require more expensive machining.
Longer Tool Life
A typical zinc mold lasts 10 times longer than an aluminum mold. Zinc, as a material is less abrasive and has a lower melting temperature. As a result, aluminum tooling wear is more dramatic lowering tool life and prematurely affecting part quality. If the tool and part approval cost is a large percentage of the production costs, using zinc instead of aluminum can provide significant savings.
Die Casting Process
Producing a Better Part
Zinc alloys are tough and have high fluidity when the alloy is molten. This produces a precise and resilient casting with greater impact resistance and rigidity than its plastic and aluminum counterparts.
The surface of a zinc casting allows for great adhesion of many finishes to its substrate, such as powder coatings and plated finishes. These finishes provide great characteristics for visual aesthetics, corrosion resistance or increased durability.
With excellent bearing and wear properties, the variety of zinc alloys allow surfaces to act as bushings for structures in motion. In addition, zinc can be formed to join materials and thus eliminating the need for additional fasteners. These zinc characteristics allow for better part design than we could with other materials.
A Greener Option
Zinc is 100% recyclable. All byproducts of the casting process can be re-melted and cast again without degradation unlike “regrind” of various plastic materials. We can even recycle painted and plated parts and recapture the zinc for reuse, making zinc a greener alternative. Check out our Environmental Impact Policy for more on Deco’s commitment to sustainability.
Less Fuel Cost, Smaller Carbon Footprint
Zinc melts at around 800 degrees Fahrenheit. However, aluminum requires 1200 degrees Fahrenheit. Aluminum casting requires extra heat, which requires more fuel in the production process. Therefore, zinc has a smaller carbon footprint than aluminum, making it a greener option.
Call or email us today and learn how working with zinc die casting experts will make your life easier and save you time and money!