+What Is Low Pressure Die Casting?
Low Pressure Die Casting：This is a repetitive process where identical parts are cast by injecting molten under low pressure into metal dies. This process requires complex machinery similar to high pressure die casting.
Advantages
Fair production rates up to 30/ Hr
Thin wall thickness possible (2-3mm)
Better linear tolerances than gravity casting surface finish improved on gravity casting, but not up to pressure die casting standards
High Yields possible as runners and risers not required
Reduced finishing is required
Pore free castings are obtainable
Sand cores may still be used to allow complex castings die costs far lower than for pressure die casting
Castings are heat treatable
Limitations
Size of casting limited by machine size
Production rates not up to pressure die casting
Feeding thin sections through thick sections is not recommended casting weight range 5 Kg - 25 Kg
Approximate economical quantity range >1000
+What Is High Pressure Die Casting ？
High Pressure Die Casting: Pressure die casting is a repetitive process casting identical parts by injecting Aluminum into metal moulds at pressures in the order of 1000psi. Complex machinery and expensive tooling is required for this process.
Advantages
Production rates may be in the order of 200/ Hr
Thin wall thickness at 1 - 2.5mm
The best surface finish is produced by this method
Very fine grain structure is obtainedThe castings have high strength in the as-cast condition
Good linear tolerances and repeatable properties are obtained
Limitations
Size of castings limited by the machine
Sound, thick sections are difficult to cast
Core configuration may be complex to enable disassembly
Porosity may become a concern
High start up costs require long production runs to reduce the overall cost
Castings cannot be heat treated casting weight range 0.01 Kg - 25 Kg
Approximate economical quantity range > 10,000 per annum.
+ Why choose zinc die casting?
•Broad Market Appeal
Zinc die casting is ideal for products ranging from toys to electronics. components can be as simple as a sink faucet or as complex as a connector housing.
•Cost Savings
The advantages of zinc die casting are endless, as it is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Zinc die castings can provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap, threads can be cast both internally and externally, and parts can be cast with thin walls or other defining features.
•Precision
Zinc die casting produces multi-cavity, complex shapes within closer tolerances than many other production processes. In addition to producing high volume runs of virtually identical parts, it produces rugged heat and wear resistant parts that are dimensionally stable, while maintaining exceptionally close tolerances.
•EMI/RFI Shielding
The zinc die casting process produces parts with excellent EMI/RFI shielding characteristics, allowing the cast to act as an electrical ground for internal circuits. Zinc die castings are stronger than plastic parts with similar dimensions. Plus, because they do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.
•Outstanding Finish
Zinc die cast parts can be manufactured with smooth or textured surfaces, and are easily plated or finished with minimal surface preparation.
•Longer Tool Life
Thousands and in some cases millions of components of identical zinc die castings can be produced before new tooling is required.
+Major Alloy Characteristics
Alloy 3: (ZAMAK 3, ZP3, ZL3, ZP0400, ZnAl4, ZDC2)
Alloy 3 is the most widely used zinc alloy in North America. Its popularity is due to an excellent balance of desirable physical and mechanical properties, superb castability and long-term dimensional stability. No. 3 also offers excellent finishing characteristics for plating, painting and chromate treatments. It is the “standard” by which other zinc alloys are rated in terms of die casting.
Alloy 5: (ZAMAK 5, ZP5, ZL5, ZP0410, ZnAl4Cu1, ZDC1)
Alloy 5 is the most widely used zinc alloy in Europe. No. 5 has excellent castability characteristics and improved creep performance over No. 3. No. 5 castings are also marginally stronger and harder than No. 3, however, these improvements are accompanied by a reduction in ductility that can affect formability during secondary bending, riveting, swaging or crimping operations. No. 5 contains an addition of 1% copper which accounts for these property changes. When an extra measure of tensile performance is needed, No. 5 castings are recommended. The alloy is readily plated, finished and machined, comparable to No. 3 alloy.
Alloy 7: (ZAMAK 7, ZL7)
Alloy 7 is a modification of No 3 with a lower magnesium content and tighter impurities specification. This results in improved casting fluidity, ductility and surface finish, making the alloy popular where the die caster is making thin walled components requiring a good surface finish. However, several new high fluidity alloys have recently been developed with superior thin wall characteristics (see high fluidity alloy).
Alloy 2: (ZAMAK 2, ZP2, ZL2, ZP0430, ZnAl4Cu3, Kirksite)
Alloy 2 offers the highest strength and hardness of the conventional zinc alloys. The high copper content (3%) in No. 2 results in property changes upon long-term aging. These changes include slight dimensional growth, lower elongation and reduced impact performance (to levels similar to aluminum alloys) for die cast products. No. 2 alloy exhibits excellent castability and maintains higher strength and hardness levels after long term aging. No. 2 alloy is a good bearing material, and may eliminate bushings and wear inserts in die cast designs
ZA-8: (ZP8)
A good gravity casting alloy, ZA-8 can also be hot chamber die cast and is readily plated and finished using standard procedures for conventional zinc alloys. When the performance of Alloys No. 3 or No. 5 is in question, ZA-8 is often the die casting choice because of high strength and creep properties and efficient hot chamber castability.
ZA-12 is the best gravity casting alloy for sand, permanent mold and the graphite mold casting process. It is also a good (cold chamber) die casting alloy. ZA-12 often competes with ZA-27 for strength applications. An excellent bearing alloy, ZA-12 is also platable, although plating adhesion is reduced compared to the conventional zinc alloys.
ZA-27: (ZP27)
This is an exceptionally strong alloy with a reported yield strength of 380 MPa (55ksi). It is light, and has excellent bearing and wear performance. Like ZA-12, this is a cold chamber die casting alloy and additional care is needed to ensure a sound casting. ZA-27 is not recommended for plating. When brute strength or wear resistance properties are needed, ZA-27 has demonstrated excellent performance.
ACuZinc5:
Developed by General Motors, this alloy has improved tensile strength, hardness and creep performance compared to the conventional zinc alloys. ACuZinc5’s strength and hardness properties are comparable to ZA-12. Testing has also shown ACuZinc5 to have excellent wear characteristics. Although this alloy is a hot chamber die casting alloy, it is more difficult to die cast with a higher wear rate of the shot end components in the die casting machine.
select language
Address: 101 Room, Building 1#, No 15, Changan Xingfa South Road,Changan Town, Dongguan City, Guangdong, China
Phone: +8613049349747
Email: sale2@dgenchuang.com
Viber: https://www.ecdiecast.com
INQUIRY