In 2021, the value of zinc die casting used in the automotive sector was estimated to be $3.66 billion, with significant future growth expected. This fact demonstrates its enormous scope and justifies a discussion on the subject.
To educate our readers, we will cover the specifics of the hot chamber die-casting process, highlight the significance of zinc die-casting for automotive parts, and offer a wide range of examples and comparisons.
Zinc die casting is a popular manufacturing method that produces high-precision, lightweight, and economical parts. The procedure uses a mold with a cavity that is shaped like the geometry of the desired part. A pressurizing mechanism pumps molten metal into this cavity, which keeps it at high pressure until it cools. By the time the cooling cycle is complete, the metal has assumed its ultimate, nearly-net shape.
Die-cast components are strong and have a good surface finish thanks to the high pressures used during the process. Because of these advantageous characteristics, zinc alloys are very practical in the automotive industry.
There’s are some of the reasons why the automotive industry prefers the zinc casting process:
The automotive industry is quickly moving toward automation and technologies supported by AI. As a result, electronics are now embedded in many die-casting components for automobile products. For instance, many cars now have rearview mirrors with camera displays and useful information like distance scales.
As a result, components housing electrical circuitry for automobiles should have good electrical conductivity. Due to zinc's high electrical conductivity, zinc die castings are becoming increasingly common in automotive applications.
Along with the advantages above, it contributes to the superior surface quality of zinc die casting in the automotive sector. Zinc's fluidity enables it to fill the cavity, leaving no spaces between the walls and the molten metal, allowing it to capture the surface texture in its entirety and great detail. Additionally, it doesn't stick to the mold's walls either. As a result, the surface has less pitting, which greatly improves its smoothness.
Porosity is another typical cause of high surface roughness in cast parts. The surface is coarse due to the visible pores caused by casting. Due to its low porosity, zinc die casting produces a smooth, pore-free surface. Additionally, many surface treatment techniques, like painting and chrome plating, are compatible with zinc alloys. Such post-processing techniques further enhance the surface quality of zinc components.
Zinc die casting is a relatively less expensive process in the automotive industry when compared to other metals like aluminum.
Because zinc has a lower melting point and melts more quickly, it uses less energy. Its high-pressure die-casting process moves more rapidly than alternative methods. Therefore, increased productivity directly reduces the cost of production. Additionally, tooling expenses for zinc die casting are roughly 50% lower than for casting aluminum. Zinc die-casting dies have longer lives, and the overall manufacturing costs are meager.
Due to their extraordinary strength and hardness, components made of zinc die-casting are perfect for use in the automotive industry. Due to stringent requirements from elements like road performance, speed, user safety, etc., these qualities are very advantageous for the production of vehicles.
Die-cast zinc alloys are strong enough to withstand the intense dynamic and thermal loads that automobiles experience. They can withstand impact loading and surface abrasion thanks to their hardness.
In the automotive sector, complex geometries are usually made with zinc alloys. Zinc is suitable for features with thin walls, curved surfaces, slender parts, thin cross-sections, etc. Zinc walls as thin as 0.5 mm can be die-cast using modern machinery.
In its molten state, zinc is highly fluid. As a result, it can quickly fill the die's difficult-to-access voids. Additionally, the high pressures used in die casting lessen the final product's porosity. The part comes out stronger because there are fewer pores.
Vehicles are mostly subjected to moisture. We frequently wash our cars while driving in the rain, close to the beach, and on humid days. Corrosion-resistant automotive components are required to ensure that automobiles last a long time.
Components made of zinc die casting perform remarkably well in such humid environments and are corrosion-resistant. Regarding corrosion resistance, zinc parts typically work just as well as aluminum ones.
Zinc die casting is a near-net shape process with a repeatability of +/- 0.001 inches for small geometries. Due to its compatibility with high-pressure environments and low temperatures, it generally outshines its rival metals like magnesium and aluminum.
Another factor contributing to its superior dimensional tolerance is its higher fluidity. Because of this, it completely fills the die cavity and can keep its shape during thermal contraction.
Zinc die casting is more productive and consumes less energy and time. All of these factors make it an environment-friendly manufacturing process. Zinc components are also recyclable and frequently recovered for reusing after a vehicle's useful life.
These are some of the applications of zinc die casting in the automotive industry:
These parts must be corrosion-resistant because they frequently come into contact with water. The manufacture of these parts is a good candidate for zinc die casting.
Die-cast zinc parts are frequently used for the gears and pulleys in car seat belt units. They are strong, have the proper hardness and mechanical strength to withstand shock loads in the event of accidents, and are durable. Due to their strength, door lock housings are also made from zinc die-casting.
Zinc die casting is a popular choice for manufacturing bodies of rearview mirrors with electrical components.
Airbag enclosures and enclosures housing electrical parts like sensors and switches are examples of enclosures. Zinc is suitable for these applications due to its electrical conductivity and surface quality.
For the production of these stress-bearing components, zinc die casting meets all requirements. It possesses the necessary hardness and strength to support the high-stress loading on these parts.
In the automotive industry, hot chamber die casting is the method of choice for zinc die casting. A high-productivity, high-pressure die casting (HDPE) method benefits from zinc alloys' lower melting point than aluminum alloys (around 440oC). (660oC). This makes placing the furnace close to the die-casting setup possible without risking damage. The die and furnace are combined in the hot chamber die casting technique.
In the beginning, the furnace heats up and melts the zinc alloy. After the zinc has finished melting, it is pumped under high pressure into the die cavity, where it cools and takes on its final shape. This method is significantly more effective than cold chamber die casting, which requires a lot of time and resources because there is no built-in furnace, and the molten metal must be transferred manually or automatically to the die. In cold chamber die casting, the metal must be heated above its melting point to keep it molten during transfer to the die.
Ares Prototyping offers high-quality zinc die-casting services for the automotive industry. We provide a large selection of zinc alloys at affordable prices. Additionally, our strong facilities ensure the excellence of our zinc die-casting services, quick turnaround times, and stringent quality inspection requirements.
Our team ensures you get the best service to satisfy your needs. To help you make decisions, we also offer thorough Design for Manufacturing (DFM) analysis. Contact us today, and let’s get started!
Zinc die-cast automotive components face fierce competition from aluminum die-cast components. The advantages of zinc die casting in the automotive sector are already well known. Due to their low melting temperature, high strength and hardness, fine surface finish, and good electrical conductivity, zinc auto parts are compatible with hot chamber die casting. Additionally, zinc auto parts have excellent corrosion resistance and thermal conductivity.
Since aluminum has a higher melting point than other materials, it can withstand operating temperatures. In comparison to their zinc counterparts, they are also lighter. Additionally, like zinc, aluminum auto parts only need minimal finishing. However, it should be noted that they are co not better than do not zinc. Additionally, aluminum components have a lower tooling life and higher manufacturing costs. Auto parts made of zinc and aluminum generally have advantages and disadvantages. Engineers and business owners concur that zinc offers more benefits and is a superior material choice for die-casting applications. However, aluminum's low density and thermal characteristics also contribute to its widespread popularity.
We hope that reading this article was educational for you. Although it is frequently disregarded, zinc die casting is an essential process with a wide range of applications in the automotive sector.
We talked about the advantages and uses of zinc die casting in this article, described the hot chamber die casting process, and contrasted zinc and aluminum auto parts. We recommend Ares Prototyping premium zinc die-casting services. Please contact our knowledgeable team for advice on your rapid prototyping projects.
