Introduction
In the automotive industry, zinc has been a pillar raw material for die casting because it has a remarkable mixture of precision, strength, durability and cost-effectiveness. Automakers are also turning to the use of zinc alloys in those parts that demand tight tolerances, thin walls, high surface finishes, wear and corrosion resistance.
This is used in common applications such as door handles, lock housings, seat belt mechanisms, gears, brackets, sensor housings and inner trim pieces.
The technology is to inject high-pressure molten zinc into steel moulds, which can be of complex geometry and volumes with limited secondary machining. Chinese Mold Manufacturer has already dominated the world of zinc die casting by being able to offer tailor-made prices, facilities and the necessary certification, such as the IATF 16949, that is required by automobile suppliers.
This paper summarizes the top trykkstøping av sink service companies focusing on automotive parts, based on the capabilities of the companies, customer reviews and industry reputation. We are targeting the Chinese manufacturers, who are the major source of worldwide provision of low-priced yet high-quality motor parts.
Key Advantages of Zinc Die Casting
- Thin wall: It enables lightweight components to be used without compromising the strength, which will result in fuel efficiency of the vehicle.
- Great accuracy and tolerances: Often net shape, eliminating or minimizing secondary machining.
- Excellent surface finish: Zinc die casting has ideal visible or plated parts.
- Cost-effectiveness: The cycle time is shorter, and the tools made from zinc die casting have a longer life than those made from aluminum or pressstøping av magnesium.
- Holdbarhet: High thermal cycling impact resistance and stability.
With the latest development of vehicles towards electrification and lightweighting, zinc die casting services are important to making dependable, high-performance components.
Støpeprosessen i sink
Zinc die casting is a very efficient production process that is accurate in making complex metal parts that have superior surface finishes. It is especially well used in the auto industry with parts that have thin wall requirements, are high strength and have better plating compatibility. Just like trykkstøping av aluminium, zinc employs the hot-chamber process because it melts at a lower temperature (approximately 420 °C), providing it with short cycle times and extended tool life.
Principles of the Zinc Die Casting Process
Mold Preparation
To ease ejection and temperature control, the steel die (mold) is sprayed with lubricant. The mold is made from strengthen material like steel that contains all the details of the automotive parts.
Melting and Injection
Zinc alloy (usually Zamak 3, 5 or ZA-8) is melted in a furnace that is connected to the machine. A gooseneck plunger is inserted into the molten metal and forces the final under high pressure (as much as 30 MPa) into the die cavity.
Solidification
The metal solidifies (a few seconds) in the water-cooled die, and the metal is solidified in its form of choice.
Utstøting
The die is cast, and ejector pins push out the casting. The final shape of the product is solidified.
Trimming og etterbehandling
Flash (runners) is removed. The secondary processes, such as machining, plating or powder coating, are included. Trimming the unwanted part of the zinc automotive product is the final step.
Why Zinc Die Casting is Superior in Automotive Applications
Zinc alloys (i.e., Zamak 3, 5, and ZA-8) have distinct advantages compared to such alternatives as aluminum:
High Quality Finish and Surface Finish
Zinc fluidity allows adding thinner walls (down to 0.5mm) and finer details to minimize the post-processing. The automotive parts made from zinc have thinner walls and greater strength.
Increased Strength and Impact Resistance
Suited to components with safety-critical functions such as seat belt retractors and locks. The automakers preferred using these products.
Extended Tool Life
Due to the low melting point, zinc die casting products’ life is increased, and high-volume runs have reduced costs.
Outstanding Plating Compatibility
The process of zinc die casting is ideal for exterior or interior parts, as these are chrome-plated.
Economical with Medium Volumes
The automotive parts made by zinc diecasting use hot-chamber processes and have faster cycle times than aluminum.
Zinc vs. Aluminum Die Casting Comparison for Automotive Parts
Automotive parts could be made from zinc or aluminum. Here is the comparison table for the users to make the best decision according to their need of product.
| Funksjoner | Pressstøping av sink | Pressstøping av aluminium |
| Wall thickness | Thinner (0.5-1.5mm) | Thicker (2-5mm) |
| Vekt | Høyere | Høy |
| Melting point | Lav | Høy |
| Thermal conductivity | Høy | Lav |
| Motstandsdyktighet mot korrosjon | Høyere | Lav |
| Impact/strength | High impact resistance | Greater ductility |
| Tool life | Longer | Shorter |
| Kostnader | Better for smaller parts | Better for larger parts |
| Bruksområder | Auto marine Power steering system Fuel system Engine system | Automotive components Aerospace House appliances Medical automotive |
Best Die Casting Providers of Zinc
Die Castings China (CNM Tech)
This is a company that deals with trykkstøping av sink and aluminum in the automotive parts industry in Dongguan, which is a die-casting hub. They have machines ranging from 120 to 1600 tons and in-house machining, deburring, plating, and powder coating.
Strengths
full service (one-stop), IATF 16949-certified, high concentration on automotive (e.g., brackets, housings). High-quality deburring provides parts without an accent.
Customer Reviews
Compliments on consistency, speedy delivery and competitive prices. Plated finishes are ideal for OEMs.
Rating
4.8/5 -Dependable when using on mid-to-high volume automotive runs.
GC Precision Mold Co, Ltd.
GC, a produsent av trykkstøping av sink, was founded in 1999 in Dongguan, and it provides IATF 16949 certified zinc, aluminum and magnesium die cast. They cover the automotive, electronics and hardware industries.
Strengths
Large assortment of alloys, integration of CNC machining, and extreme care to tight tolerances. Verified in automotive components such as gears and housings.
Customer Reviews
Customer satisfaction rating (transparency, responsiveness, and consistency of quality) was high. Customers report about superior English communication.
Rating
4.9/5 -Best selection of precision automotive parts.
Sincere Tech (Dongguan Sincere Tech Co., Ltd.)
Although its major operations are plastic injection and general die casting, Oppriktig teknologi also offers zinc die casting services, together with machining and assembly. They refer to die cast of metal components, including the automobile.
Strengths
All-in-one services (design to assembly), ISO 9001:2015, 18 plus years of experience. DFM and fluent English assistance.
Customer Reviews
Favorable response towards project management and problem-solving. Excellent in problem-solving according to foreign clients.
Rating
4.7/5: Strong on combined projects of zinc and plastic parts.
PHB Inc.
PHB is a hundred-year-old American company that deals with aluminum and zinc die casting. They work with large car manufacturers, making components such as drilling, milling and brackets.
Styrke
Such strong aspects as IATF 16949 certification, in-house tooling, and turnkey services between design and finishing are present. On-time delivery, quality, and the ability to solve complex parts are the characteristics that were brought up in the reviews.
Bruksområder
The company has applications in the automotive, safety equipment and appliances manufacturing. The company is making many pieces of safety equipment using aluminum and zinc die casting.
Dynacast (member of Form Technologies)
As an international player, Dynacast is known to perform precision zinc die casting in the use of automobiles, such as safety systems and protection housing for electronic components. They have multi-site operations, and they focus on innovation. They are ranked as a leading player with high investment in R&D in the market reports.
Brushi
Bruschi is an Italian expert who specializes in complex zinc parts that are applied by motor vehicle manufacturers in the exterior and interior parts of the doors and the sunroof parts. They focus on the optimization of designs and sustainability. They are rated highly in the industry analyses in terms of quality and precision.
Pace Industries
Pace also offers wide-ranging die cast services, zinc in automotive transmission and automotive engine components. Their concentration is on lightweight solutions with North American facilities. It has been reported that there is excellent customer support and competitiveness in terms of price.
Considerations in Selecting a Zinc Die Casting Provider
- Certifications: IATF automotive quality standards.
- Potentialities: Hot-chamber machine, secondary (plating, machining).
- Experience in automotive (e.g., safety-critical parts).
- Bærekraft: Zinc can be recycled.
- Location and Lead Times: Logistics proximity.
- Customer Reviews: Dwelling on reliability, communication, and defects.
Applications of Zinc Die Casting
Zinc die casting is a flexible process of manufacturing high-precision, long-lasting parts with high-quality surface finishes, thin-walled, and intricate geometries. It is best in various industries because of its benefits, which are high strength, impact resistance, dimensional stability, and cost-effective high-volume production.
Bilindustrien
Zinc die casting is predominant in this area, where modern die casting is based. It is applied in door handles, brackets, carburetors, seat belt parts, brake parts, and interior trims because of its strength, resistant to corrosion and lightweight qualities.
Elektronikk
Zinc has a higher electrical conductivity and shielding, making it ideal in housings, connectors, heat sinks and enclosures used with devices such as smartphones, laptops and regulators. It is also reliable in severe conditions and allows complex designs.
Forbruksvarer
Zinc components are used in household products in the form of locks, faucets, door handles, furniture fittings, and appliances due to their beauty, durability, and the ability to be plated without much difficulty.
Construction Industry
Precision and durability are useful in other industries such as hardware construction (hinges, fixtures), plumbing (valves, fittings), industrial machinery (gears, pumps) and medical equipment.
In general, zinc die casting allows an efficient and sustainable manufacturing of net-shape parts to cut down the machining requirements and facilitate innovation in challenging applications.
Konklusjon
Zinc die casting, as a technology, is essential to the automotive industry as it moves to scale with higher precision, durability, and safety requirements through electrification, lightweighting, and optimization of safety automation.
Its special properties, such as thin walls, high surface finish, high plating compatibility, impact resistance, and high-volume production, enable zinc alloys to be used in important components such as door locks, seat belts, sensors, and decorative trim.
Market leaders such as those in the manufacturing centres in China, such as Dongguan, are dominating the market with a combination of state-of-the-art hot-chamber, IATF 16949 and one-stop design to finishing services.
The companies, including GC Precision Mold, Die Castings China (CNM Tech), and international participants, including Dynacast and PHB, continue to provide superior quality, which earned them excellent ratings in terms of reliability and communication, as well as innovation.
In the automotive OEM and suppliers that are interested in balancing performance, weight and cost, particularly in the expanding EV market, it is essential to collaborate with a qualified zinc die casting company.
Vanlige spørsmål
How does zinc produce the automotive parts through die casting? What are the primary benefits of the process?
The hot and cold chamber die casting is used for making automotive products from zinc. Zinc die casting will be more readily available in thin walls, high-precision, good surface finish, strength, and high-volume production, being cost-effective.
What are some of the most common automotive components that are die-cast using zinc?
Some of the most readily available automotive components are door locks, seat belt parts, carburetors, sensor covers, brackets and internal trim.
What is the comparison of zinc die casting with aluminum use in automobiles?
Zinc die casting offers superior accuracy and finish, and mechanical cycles, and aluminum is lighter when dealing with large structural items.
What are the certifications required of a zinc die casting supplier in the case of automotive?
IATF 16949 is a mandatory requirement, as well as ISO 9001.
Is die casting of zinc eco-friendly?
Yes, zinc can be completely recycled and minimum wastes are produced in the process.
Are zinc die-cast parts platable or finishable?
Yes, zinc is a great plating material (chrome, nickel) used in the aesthetic and corrosion-resistant automobile use.
What is the average lead time of die-cast automotive parts that are made of zinc?
From prototyping to making the zinc die casting requires weeks for the large-volume production. At the same time, the short cycles are required because of the hot-chamber efficiency.
