Ever wonder how complex shapes made of steel came to be? It is because of the technology known as die casting. Die casting involves the process of molding molten metals into complex shapes. Die cast metals are parts of almost all things we use today from toys to automobiles.
In the past die casting was done using metal alloys like tin and lead. When zinc and aluminum alloys were introduced in 1914, zinc die casting became the new favorite in the industry. Among all the alloys used in die casting, zinc is the easiest to cast. It is highly ductile and is very strong. It is the metal alloy of choice in making small metal parts because it is very economical.
Zinc die casting is better than other manufacturing techniques. Here's why:
- Better than plastic moldings. Zinc die casting produces stronger parts that are more resistant to heat and weathering compared to plastic molded parts.
- Better than sand castings. Parts made by sand casting techniques have thicker walls and coarser surfaces. Zinc die castings have the opposite.
- Better than forgings. Zinc die castings can make cast coring holes that are not possible with forgings.
- Better than stamping. Stamping techniques are more time consuming. Zinc die casting produces the same quality in less time, therefore producing more products at less assembly time.
- Better than screw machine products. Bar or tubular stocks cannot produce the complex shapes that zinc die casting can. There is also less waste and scrap in using zinc die casting.
Aside from these comparisons, zinc die casting has additional advantages, too. These include the following:
- Economical and efficient. Since you can produce almost anything out of zinc die casting, there is no need to use any other material at all. Everything that is used in building, let's say a toy for example, can be made with zinc die casting. Holes can be set and threads can be cast, and that makes assembly faster and easier.
- Can withstand wear and tear. Materials made of zinc die casting can withstand extreme heat and pressure compared to other materials.
- Excellent finish. It is easy to make parts that can either be smooth or textured by using the zinc die casting technique. The ductility of the zinc alloy makes it an easy material to play with during the course of molding.
- Longer tool life. Zinc is a durable alloy, which makes parts made with it have a longer tool life. Using zinc with steel also protects it from rust.
- Produces excellent EMF/RFI shielding characteristics. This enables zinc die casting materials to act as an electrical ground for internal circuits.
There is great demand for materials made of zinc die casting, especially in the industrial market. Zinc die casting is used in automobiles, pipes, valves, plumbing fixtures, toys, and many more roles. The strength, lightness, and cost-effectiveness that is tied up with zinc die casting makes it the most preferred system among industry players.