Custom Online Zinc Zamak Die Casting Service

Our Custom Online Zinc Die Casting Service offers high-quality, precision castings with rapid prototyping, efficient post-processing, and a wide range of casting materials. We provide tailored solutions for various industries, ensuring fast turnaround and cost-effective manufacturing.

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What Is Zinc/Zamak Die Casting?

Zinc/Zamak die casting is a process where molten zinc alloy is injected into a mold under high pressure to create precise, durable parts. This method is ideal for producing complex shapes with excellent dimensional accuracy, strength, and surface finishes.

Steps	Description
Mold Preparation	High-strength steel molds are designed with cavities to shape the molten zinc alloy. The mold is coated with a release agent to facilitate easy part removal and smooth finishes.
Zinc Alloy Melting	Zinc alloy is heated in a furnace at temperatures around 380°C to 430°C. The molten alloy is then ready to be injected into the die casting machine for molding.
Zinc Injection	The molten zinc alloy is injected into the mold under high pressure (usually 20,000 psi). The injection process fills all mold cavities quickly and precisely for part formation.
Cooling and Solidification	After injection, the molten zinc cools and solidifies within the mold, quickly forming the part. Cooling time depends on the part's size and complexity.
Trimming and Finishing	After solidification, excess material (gates, runners) is removed. The die-cast part undergoes additional processes like machining, polishing, or surface treatments for precision.

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Benefits of Zinc/Zamak Die Castings

Aluminum die castings offer numerous benefits, including high dimensional accuracy, lightweight yet durable parts, design flexibility for complex geometries, and cost-effectiveness for mass production. These advantages make aluminum die casting ideal for industries like automotive, aerospace, and electronics.

Benefits	Description
High Dimensional Accuracy	Zinc/Zamak die casting offers excellent dimensional precision, enabling the production of parts with intricate details and tight tolerances. This high accuracy reduces post-processing requirements and ensures parts meet exact specifications.
Durability and Strength	Zinc/Zamak die castings deliver high strength, durability, and resistance to wear and corrosion. These properties make them ideal for applications requiring reliable performance in harsh environments, like automotive and electronics.
Cost-Effective for Mass Production	Zinc/Zamak die casting is an efficient and cost-effective process for large-scale production. Its high speed, repeatability, and minimal waste make it ideal for producing high volumes of complex parts at lower costs.
Complex Geometries	Zinc/Zamak die casting allows the creation of parts with complex shapes, thin walls, and intricate features. This design flexibility reduces the need for additional processes, enabling the production of detailed and lightweight parts.

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Typical Casting Zinc/Zamak Alloys

We offer a range of high-quality aluminum alloys for die casting, including A356, A360, A380, ADC12 (A383), B390, A413, and anodized aluminum. Each alloy provides unique properties suited for various industries like automotive, aerospace, and electronics.

Zinc/Zamak Alloys	Aliases	Tensile Strength (MPa)	Yield Strength (MPa)	Fatigue Strength (MPa)	Elongation (%)	Hardness (HB)	Density (g/cm³)	Applications
Zamak 3	ZA-3 (US), ZL3 (EU)	260-310	200-240	100-150	1-3%	80-100	6.60-6.70	General-purpose die casting, automotive parts, hardware
Zamak 5	ZA-5 (US), ZL5 (EU)	270-340	210-250	110-160	2-4%	85-110	6.60-6.70	Electronics, automotive components, decorative parts
Zamak 2	ZA-2 (US), ZL2 (EU)	350-400	250-300	130-180	1-2%	90-120	6.70-6.75	High-strength applications, automotive parts, hardware
Zamak 7	ZA-7 (US), ZL7 (EU)	220-270	180-220	80-120	1-2%	75-95	6.65-6.75	Precision die casting, thin-walled parts
Zamak 8	ZL8 (EU)	240-300	190-230	100-140	2-3%	80-100	6.60-6.70	High-performance applications, automotive, appliance parts
ZA-8	ZL8 (EU)	340-410	250-300	130-180	2-3%	95-120	6.70-6.75	High-strength structural components, automotive parts
Zamak 12	ZL12 (EU)	240-300	190-230	100-140	2-3%	85-100	6.60-6.70	Automotive, machinery, general-purpose parts
Zamak 27	ZL27 (EU)	340-380	250-300	130-180	3-4%	90-120	6.65-6.70	High-performance applications, industrial components
Zinc-Aluminum	ZAMAK 27A	300-380	220-270	120-170	2-3%	90-115	6.60-6.75	Structural parts, industrial and automotive parts

Typical Surface Treatment for Zinc Die Castings

Typical surface treatments for zinc die castings include chromate conversion coating, powder coating, electroplating, painting, polishing, shot blasting, vibratory finishing, chemical etching, clear coating, and PVD. These processes enhance properties such as corrosion resistance, surface hardness, appearance, and strength, while also improving durability and performance in various industrial applications.

Surface Treatment	Description	Purpose/Benefit	Applications
Chromate Conversion Coating	A chemical treatment that creates a protective layer on the zinc surface.	Provides corrosion resistance and improves paint adhesion.	Automotive, electrical components, military, and industrial equipment.
Powder Coating	A dry finishing process where a powdered coating is applied and then cured under heat.	Enhances corrosion resistance, improves aesthetics, and offers durable finishes.	Automotive parts, household appliances, furniture, outdoor equipment.
Electroplating (Nickel, Zinc, etc.)	The process of depositing a metal layer onto the zinc surface through electrochemical means.	Improves corrosion resistance and surface hardness, and enhances appearance.	Automotive, electrical components, hardware, decorative items.
Painting	Application of liquid paints for decorative and protective purposes.	Offers color, increased durability, and corrosion resistance.	Consumer products, automotive, machinery, outdoor products, furniture.
Polishing	Mechanical or chemical polishing to create a smooth, shiny surface.	Improves surface finish and aesthetic appeal, often used for decorative purposes.	Jewelry, automotive, consumer electronics, decorative architectural elements.
Shot Blasting	High-pressure blasting of abrasive particles onto the surface to clean or texture it.	Improves surface texture, removes casting defects, and enhances paint adhesion.	Metalworking, automotive, aerospace, construction, foundries.
Vibratory Finishing	Using abrasive media in a vibrating machine to smooth surfaces.	Reduces surface roughness and deburrs parts.	Automotive, aerospace, medical device manufacturing, jewelry finishing.
Chemical Etching	Use of chemicals to etch away unwanted material from the surface.	Provides fine surface finishes, often used for engraving or creating textured finishes.	Electronics, signage, jewelry, precision machining, aerospace.
Clear Coating	Application of a transparent coating to preserve the natural finish of zinc.	Provides UV and corrosion resistance while maintaining the metallic look.	Automotive, electronics, marine, architectural, jewelry.
PVD Process	Physical Vapor Deposition process that applies thin metallic coatings to the zinc surface.	Provides superior wear resistance, hardness, and enhanced aesthetics with metallic finishes.	Electronics, automotive, decorative hardware, medical devices, aerospace.

Applications of Zamak Die Castings

Zamak die casting offers precision, durability, and cost-effective solutions across industries. Ideal for automotive door handles, corrosion-resistant electrical connectors, and consumer electronics casings, it ensures strength and intricate detailing. From secure lock mechanisms to fashion accessories, medical device housings, and industrial machinery parts, Zamak die casting enhances performance and reliability.

High-Strength Zinc Die Casting for Intricate Fashion Accessories and Jewelry

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Advanced Zamak Die Casting for High-Quality Furniture and Decorative Hardware

High-precision Zinc Zamak Die Casting for Durable Automotive Door Handles

Custom Zamak Die Casting Service for Corrosion-Resistant Electrical Connectors

Precision-Manufactured Zinc Alloy Die Cast Components for Consumer Electronic Casing

Durable Zamak Die Cast Lock Mechanisms for Security and Hardware Applications

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Zinc Die Castings Design

Good design in zinc die castings offers enhanced strength, improved surface finish, and reduced porosity. It ensures optimal metal flow, uniform wall thickness, and precise dimensions, minimizing defects and improving part durability. Efficient design also reduces material waste, lowers production costs, and shortens lead times, ultimately improving the quality, functionality, and cost-effectiveness of the final product.

Design Elements	Specific Value/Range
Uniform Wall Thickness	Aim for wall thickness between 1.5mm to 4mm for optimal casting flow and to reduce material wastage.

Draft Angles	Use a 1° to 3° draft angle on vertical surfaces to ease part removal and prevent damage to the mold.

Radii and Fillets	Incorporate 2mm to 4mm radii at corners and edges to improve flow and reduce stress concentrations.

Avoid Sharp Corners	Sharp corners can cause stress and are difficult to cast. Use a minimum 2mm radius to improve moldability.

Incorporate Ribs and Bosses	Design ribs with a thickness of 0.5mm to 1mm and maintain proper spacing (2-3 times the thickness) for strength without adding excessive material.

Correct Gate Placement	Gates should be placed at the thickest sections, and the gate thickness should be about 1mm to 2mm to ensure even metal flow and avoid cold shuts.

Optimized Thickness for Strength	For balance, wall thickness should be between 1.5mm to 4mm, ensuring a lightweight and durable part.

Proper Tooling Design	Vents should be spaced about 30mm to 50mm apart, with runners about 5mm to 7mm wide to ensure proper air evacuation and metal flow.

Consider Post-Processing Needs	Allow for 0.1mm to 0.3mm tolerance for any CNC machining or secondary finishing, such as polishing or painting.

Avoid Deep Blind Holes	Avoid blind holes deeper than 2-3 times their diameter. If needed, use through holes to simplify casting.

Minimize Undercuts	Minimize undercuts in the design to reduce complexity in tooling. Consider using side-action tooling or simplifying the design.