Characteristics of Zinc Alloy Die Casting

High Pressure & Speed: Injection pressure ranges from thousands to 200,000 kPa. Filling speeds reach 10-50 m/s (sometimes >100 m/s) within 0.01-0.2 seconds.

Advantages vs. Other Casting Methods:

1. High Precision & Quality:Excellent dimensional accuracy (grade 4-7), surface finish roughness (grade 5-8), the strength is generally 25% to 30% higher than sand casting, but the elongation decreased by approximately 70%. Capable of casting thin-walled and complex like thin-walled parts (e.g., min. wall: Zn 0.3mm, Al 0.5mm; min. hole: 0.7mm; min. pitch: 0.75mm).

2. High Volume Production:High machine rates (e.g., 600-700 shots/8h cold-chamber; 3000-7000 shots/8h hot-chamber). Long die life (100,000s to 1,000,000s shots). Easily automated.

3. Cost-Effective:Minimal machining needed, saving material, equipment, and labor. Suitable for multi-material inserts.

4. Surface Ready:Easily electroplated, painted, or powder coated.

Disadvantages:

1. Porosity risk limits heat treatability due to turbulent high-speed filling.

2. Challenging for parts with complex internal cavities.

3. Shorter die life with high-melting-point alloys (e.g., Cu, Fe).

4. High tooling cost makes small batches uneconomical.

5. Limited to specific alloys (Zn, Al, Mg, Cu, Sn, Pb); Cu has the highest melting point.

Key Applications:

1. Connectors:Housings, shells.

2. Smart Home:Furniture fittings, housings.

3. Automotive:Connectors, interior trim, accessories.