The zinc die casting process is famous for producing components in the construction and industrial fields. However, it is most commonly applied in the automotive industry, and it is noteworthy to mention that this process was initially designed for this industry. Today, many parts of vehicles can be crafted by die casting.
In the process of casting, there isn’t usually a need for further machining. That is so not only because of the high accuracy of the process, but casted components have a pleasant finish and can be used raw. The use of zinc in the die casting process is increasingly popular in the automotive industry. It is also gaining prominence in the hardware and building sectors.
Zinc is now one of the essential metals in the automotive industry, particularly for products such as pulleys in seat belt systems, retractor gears, pawls, and door lock housing. It can also feature in making sensor and camshaft components. It is possible to realize a level of malleability, ductility, and strength that other materials don’t have by using zinc and its alloys for die casting. Zinc has proven to be a good choice for obtaining top-quality aesthetic parts with high tolerances for shape morphology that other materials do not offer and making grooves for gear or mechanical parts.
Components of automotive zinc die casting
Besides using zinc alloy for creating automotive components, it is also helpful for electroplating purposes due to its numerous benefits, including enhancing the anti-corrosion zinc property. Below is a list of examples of the components that can produce with zinc plating.
- Fuel systems
- Climate control components
- Parts in the seat belt system
- Chassis hardware
- Air conditioning components and systems
- Brake parts and systems
- Power steering systems
- Engine and other beneath-the-hood components
- Mechanical parts
- Sunroof parts
- Interior aesthetic parts
Advantages of using zinc alloys
Zinc alloys make it possible to develop and provide durable, simplified die-cast end-products. The stability, flexibility, and strength of zinc allow experts to obtain a more suitable and resistant product. This high flexibility makes zinc alloy suitable for die casting, which requires the sustenance of pressure band expansion without experiencing fractures. Other advantages of using zinc alloys in die casting are:
- High-quality chrome plating and coating: Components made of zinc die casting are fit for electroplating.
- Quality finishing and complex geometry: You can precisely cast intricate, technically demanding, and thin-walled parts.
- Low melting point: Zinc has a low melting point, which means that you’ll expend lesser energy for production.
- It is economically efficient for making small components
- Thin walls: Zinc alloys contribute to anti-corrosion properties in end products, thus enhancing their durability in adverse environments.
- Strong stability: This attribute helps to derive long-lasting products with top-quality finishing.
- Low cost of raw materials
- Standard electrical and thermal conductivity
Zinc is practically more suitable for castings with high detailing. It also does not require much finishing work or machining after the component is ejected from the die, which gives cost advantages. The low melting and pressure points also help reduce the incidence of thermal shock. Zinc is a non-sparking metal; thus, it is free from the risks of producing sparks, making it suitable for use in any environment.