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The importance of zinc die casting in the automotive industry

Zinc die casting

What is Die Casting?

Die casting is a metal casting process which is characterized by pressing molten metal into the mold cavity. The mold cavity is made using two hardened tool steel molds that are worked on during processing and work similarly to injection molds. Most die-casting is made from non-ferrous metals, especially zinc, copper, aluminum, magnesium, tin, lead, and tin-based alloys. Depending on the type of metal being thrown, a thermal or cold engine is used.

Zinc die casting

Zinc die casting

The zinc die casting process is very popular for making parts in building and industrial fields, but the most common application is in the automotive industry. In fact, cars have different parts that can be made through die casting, in such a way that the modern process of die casting was originally started for the automotive industry.

With the casting process often no further machining is needed after casting: not only is the accuracy up to 99.8%, but the casted products can also be used raw because they have a pleasant finish. The use of zinc die casting is almost 28% in the automotive industry, followed by the building and hardware sector.

Zinc has become one of the most important metals in the auto parts industry, especially for products such as door lock housing, pawl, gears and retractor pulleys in seat belt systems, but also for camshaft and sensor components. By using this metal and its alloys, it is possible to achieve strength, ductility, and flexibility that would not be possible with other materials.

In addition, zinc can be the right choice to get high-quality aesthetic components, with tight tolerances that are not possible with other materials, and to get embossing and grooves for mechanical components or gears.

Zinc Die Casting Mechanisms in Automotive

As said before, the automotive industry is the most common die casting application: using zinc and its alloys makes it possible to produce components that are able to achieve high aesthetic quality, with tight and narrow tolerance for shape morphology. Zinc alloys are also used for coatings because of its many benefits, such as improving the anti-corrosion properties of zinc which are already impressive.

Below you can find a number of possible examples of zinc plating:

  • Interior aesthetic section
  • Sunroofs Section
  • Mechanical parts
  • Engine and other underhood components
  • Power steering system
  • Parts and brake system
  • Air conditioning components and systems
  • Chassis hardware
  • Parts in the seat belt system
  • Components of climate control
  • Fuel system

Advantages for Zinc Die Casting:

  • An efficient & economical process offering various forms & forms possible.
  • High-Speed ​​Production
  • Dimension Accuracy & Stability
  • Strength & weight
  • Several finishing techniques are available
  • Simple Assembly

The Die Casting process began with the use of lead and lead alloys, magnesium and copper alloys which were quickly followed, and in the 1930s, many modern alloys still in use today are available. This process evolved from casting low-pressure injection to modern high-pressure injection of 4,500 pounds per square inch. The modern process is capable of producing high integrity, clean casting forms with excellent surface finishes.

Zinc casting alloy is a strong, durable and cost-effective engineering material. Their mechanical properties are competitive and are usually higher than cast aluminum, magnesium, bronze, plastic and most cast iron.

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The Die Casting Process Step By Step

Die Casting manufacture company

The climbing phase:

  • The 1st step is to prepare the die halves for casting by cleaning the faces of each die then applying lubrication or release agent.
  • Once the die has been prepared, the die halves are closed and clamped together with pressure applied from the die-cast machine.
  • The clamping force will depend upon the size of the machine but must be more than the opposing force trying to open the die during the casting process.Die Casting manufacture company

The injection phase:

  • The ingots are added to the furnace and kept molten at a set temperature according to the metal being used.
  • The molten metal is transferred to an injection chamber and injected into the closed die pressure ranging from 1000 to 20,000 psi.
  • The pressure is maintained while the metal solidifies.
  • The amount is injected into the die is known as the ‘shot’
  • The injection of metal into the die is very short, this ensures the metals do not start to solidify before the die is completely filled.

The cooling phase:

  • After the injection is complete, the molten metal needs to solidify before the die is opened.
  • The cooling time will depend upon the part geometry as well as the metal thermodynamic properties.
  • The wall thickness of the parts plays a big factor in the cooling time, the thicker the wall section the longer the cooling time required.

The ejection phase:

  • After the cooling time has elapsed, the two die halves can be opened.
  • An ejection mechanism then pushes the solidified casting out of the die.
  • The force of the ejection will be determined by the size of the part, bearing in mind, the part shrink during the cooling process and tends to stick to the die surface.
  • Once the part has been ejected, the die can be closed ready for the next injection cycle.

The trimming phase

  • During the cooling and solidification phase, the casting will solidify as a complete cast unit which includes the part, flash, and any runner system
  • This excess material must be trimmed off to leave just the main cast product.
  • Method of trimming includes trim tools, band saw are manually clipping.
  • Any trimmed metal is either scrapped or recycled if permitted.

Advantages of die casting:

  • Die casting is fast

Die casting can be produced in seconds each part and quantities of hundreds to thousands of metal parts each day.

  • Near net shape

Die casting are produced “near net shapes” no matter how complex the shape are how tight the tolerances are.

  • Lighter weights

Die casting are stronger because of the material surface skin not the thickness of materials so parts can weigh less with thinner casting wall thicknesses.

  • Die casting is versatile

Many more part shapes and sizes can be produced using the die casting manufacturing process.

  • Die casting are durable

Die castings parts are metal and have a long service life.

  • Die castings are inexpensive

Die castings are fast to produce and useless material. Die casting are typically less expensive than most other metal parts manufacturing processes.

 

 

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What Is Zamak Zinc Die Casting Parts

Zinc die casting Parts is referred to as the hot-chamber process. It is the method by which zinc (zamak) is heated under high temperatures and the molten material forced into a zinc die casting mold under high pressure to produce product with a similar shape as the die. As the metal moves through the die, air escapes through the vents. Once the die is full, the high pressure is maintained until it solidifies and the die is separated to release the finished zinc cast. After casting, no further modification is usually required.

Use of Zinc Die Casting

Zinc (zamak) is known for its high strength, accuracy, ductility, ease of casting, high thermal and electrical conductivity, and long life. As such, the zinc die casting is applied in the manufacture of high quality industrial and building materials. Die casting started in the automotive industry and it is still widely used in the manufacture of automotive components. The door locks casing, pulley, and the camshaft are some of the car parts that are made of zinc casting. In the construction industry, zinc die casting is utilized in the manufacture of components such as door knobs, faucets, and roofing. On the other hand, there are many zinc casting machine parts, such as electrical fittings.

Zinc Die Casting Process

Zinc is cast using the hot-chamber process due to its low melting temperatures. Cold chamber process is applied in the casting of metals with high melting temperatures such as the aluminium. The zinc die casting process involves the preparation of the metal, die preparation, and finishing. It commences with the preparation of the die followed by the metal. Notably, the die can be used once or severally depending on the component being manufactured. If it was used before, it should be lubricated to ease the removal of the cast metal. Afterwards, the ejector die half and the cover die half are screwed. The cover die half has a sprue through which the molten metal is injected while the ejector die has ejector pins for removing the castings.
Preparation of the die is followed by melting of the ZA or the ZAMALAK alloy on a furnace. The physical properties of the product dictates the choice of the alloy. Due to metal hardness and strength, the furnace temperature is usually very high. The oxidized parts of the metal are removed at this stage to raise the purity of the finished product. Various chemicals can be added to improve physical properties of the finished alloy.
Once the molten metal is prepared, it is injected into the feed system under high pressure. Most of the systems have several dies for efficiency and mass production. The raised pressure ensures that the molten zinc alloy gets into the mold as fast as possible, no air gets into the molten metal, and the expulsion of the air in the die through the vents. After filling the die, the pressure is raised further until the zinc alloy casting solidifies. The process also involves cooling using water. Then, the two dies are separated and the metal cast is removed. This is followed by the cleaning of the feed system to get rid of the flash. Further finishing can be carried out depending with the final use of the product. The runner that is removed from the final product and the flash are usually recycled.
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Die Casting Parts

Die casting parts

Machining and Finishing Operations For Ready-To-Assemble Die Casting Parts.

Over 20 years, CNM die casting company, Incorporated has provided high-quality aluminum, magnesium, and zinc die casting parts and services. CNM TECH specializes in the design, engineering, and production of complex die-cast parts in a broad range of sizes. Our experienced team of engineers, technicians, designers, machinists, finishers, and production staff excel at producing precision castings that are meticulously machined to tight tolerances, finished to customer specifications, and delivered ready for assembly.

Regardless of quantity, part type, alloy, cast-and-trim to cosmetic finish, CNM TECH is a solution driven die-casting partner that works with you to produce the best possible products cost-effectively and efficiently.

In order to supply ready-to-assemble component die casting parts, CNM TECH Die Casting manufacturer maintains a fully-equipped production machine shop. It’s staffed with machinists experienced in working with aluminum and zinc. Here, modern machine tools, supported by regular maintenance and a statistical process control program, can turn out production quantities of high-quality parts to meet your manufacturing schedules. CNM TECH has the capability of handling machining requirements where tolerances must be held to a few ten-thousandths of an inch and where production quality control records must be provided.

Die Casting ManufacturerCNM TECH also maintains close working relationships with local suppliers of a variety of finishing services such as plating, anodizing and painting. This assures you of a smooth flow of work through a single, responsible source and, at the same time, provides access to a wide variety of finishing options.

Inventory capabilities to meet your just-in-time production needs.

CNM TECH warehouses parts inventories for customers with just-in-time production schedules. Once a predetermined inventory level has been established, we can set manufacturing schedules to maintain the stock you require. Actual parts delivery is aided by our central location and easy access to interstate highways.

Let’s talk about the difference that quality can make in your die casting parts.

If you’re interested in lowering your current casting reject rate or if you feel your part quantities are reaching a volume that can justify die casting, please give us a call. We’ve invested a lot of ourselves in maintaining tight quality control standards and we’d like to put that investment to work for you.

Finished parts can be packed to any specification for timely delivery anywhere in the country. CNM TECH’s location puts the entire upper Midwest within the overnight delivery time.

 

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China Die Casting Service

Aluminium die casting

Capacity To Meet Your Aluminum, Magnesium, Zinc and Vacuum Die Casting Needs.

Aluminum Die Casting

Providing high-quality Aluminum die casting parts at competitive prices requires modem die casting equipment. To reduce the effects that extreme cooling temperatures have on dies CNM TECH is converting its die cooling system from water to oil. Oil maintains a warmer die temperature that contributes to a more uniform casting and extends die life, an important factor in part costs.

CNM TECH Die Casting company is adapting robotic controls to the operation of die casting machines. This permits a substantial increase in production rates, important in both controlling costs and meeting delivery requirements. It also allows us to use our people in ways which make better use of their skills and experience.

To lower production costs, CNM TECH Die Casting manufacturer has developed and patented, new, low volume, energy efficient aluminum melting furnaces. Since aluminum can be melted efficiently in small quantities, it allows the company to supply casting machines with different alloys of aluminum simultaneously. Casting machines don’t have to stand to wait for a large furnace to supply the proper alloy. Schedules aren’t built around what alloy is in the furnace.

Zinc Die Casting

For applications where high impact strength, low cost anZinc Die Castingd close dimensional limits are important design considerations, zinc die casting plays an important role. Zinc normally permits higher production rates than aluminum and parts can be designed with thinner cross-sections. The resulting parts are highly resistant to corrosion and receptive to a variety of beautiful finishes.

High rates of production and uniform quality are maintained by die casting machines with automatic extractors.

Vacuum Die Casting

Vacuum die casting is preferred by many casting buyers because it results in a less porous part. CNM TECH’s Vert-a-Cast machines, with a clamping force of 400 tons, are capable of producing castings automatically at a much faster pace than manually-operated horizontal machines.

Vacuum die casting, a CNM TECH capability for ten years, is often the only economical way to meet critical porosity specifications.

Maintenance, repair, changes and corrections on dies are accomplished promptly in CNM TECH’s fully-equipped tool and die shop.

Alloy materials are melted, fluxed and cleaned in the central furnace before being transferred to die casting equipment.

If you have any die casting requirement, you are welcome to send us your requirement for a quotation.

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High Quality Die Casting Parts

Die Casting Parts

Your High-Quality Source For Aluminum, Magnesium and Zinc Die Castings; Machined and Finished, Ready For Assembly.

Setting product quality as the company goal, CNM Die Casting has risen to the top of its industry during the past ten years.

Die casting buyers to look to CNM TECH to help reduce reject problems they have encountered with other component part suppliers. A manufacturer of natural gas valves experienced reject levels of up to 40% until they were cast by CNM TECH. Now, very few of their parts fail to meet a rigorous 100% testing level for pressure leaks.

Quality based on engineering experience

At CNM TECH Die Casting company, quality begins with experienced engineering assistance. Consultation on part design and aluminum alloy selection are part of the service. Sometimes minor changes in part design can increase production rates and eliminate potential quality problems. The end result is a better part at a lower unit cost.

To be sure finished die casting parts to meet alloy specifications, both incoming materials and finishDie Casting Manufacturered product samples are checked on the Jarrell-Ash spectrometer.

Quality that moves with production instead of just a final part check

Production starts after a final part design is accepted. Our quality control program then begins a series of checks to determine that the part has been produced within the specified tolerances. First, alloys are tested to make sure they meet our customer’s specifications. Then, statistical sampling during the casting and machining processes provides an early warning of manufacturing defects and helps to prevent the production of defective finished parts. Inspection frequencies can be predetermined by the job requirements to make certain that the parts you receive are parts you can use.

A Three Coordinate Measuring Machine (CMM) allows completed part dimensions to be checked against computer-stored specifications to assure that accuracy has been maintained throughout the entire production run. Fatigue testing for completed parts can also be carried out under simulated operating conditions if required by the customer.

Whether your specifications call for pressure tightness, critical dimensions and details, or freedom from subsurface discontinuities, CNM TECH quality assurance people have the equipment and training for the job.

A regular inspection program on casting and machining equipment helps us maintain close tolerances. Equipment that’s in top operating condition benefits our customers in both reduced costs and shorter lead times. In-plant maintenance personnel can quickly correct machine problems and smooth production flow.

Die Casting CompanyThis online catalogue will introduce you to our capabilities and give you a brief tour of our facility. Over 150 employees share our interest in providing on-time delivery of ready-for-assembly die casting parts and our objective of striving for the highest quality.

CNM TECH engineers are available for consultation at early design stages to help assure finished parts meet tolerance and quality requirements while making economical use of die casting processes.

The dimensional coordinate measuring machine is used to measure castings against specified tolerances.

Proven, rigid quality assurance techniques applied at CNM TECH Die Casting manufacturer can meet the most demanding industrial standards.

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