Differences Between Aluminum Die Casting And Zinc Alloy Die Casting

From the creation of scale replica cars and airplanes to the durable mechanical parts housed in their real life counterparts, die casting is one of the most cost-effective and versatile manufacturing processes in the world.

Die casting is a precision process that involves injecting molten metal under high pressure into a die, or mold, of a desired shape. Dies are usually constructed with long-lasting, quality steel. Upon solidification and cooling of the material, the design, which can support a range of complex geometries and intricate details, is ejected for quenching, machining or finishing.

This process can be repeated again and again with incredible dimensional accuracy, making it one of the best ways for manufacturing a high volume of castings.

In addition, some castings can be completely finished when they are ejected from the die, which can eliminate the need for machining and additional finishing work. By offering a high-speed production process, precision and high-quality castings, die casting has become a valuable manufacturing method since its invention in 1838.

One of the most important choices to make when setting out to die cast a design is determining the type of alloy best suited to its specific application. Aluminum, magnesium, zinc, and zinc-aluminum (ZA) are the most common types of metallic alloys used in the die casting process.

Below I'm talking about the difference of aluminum die casting and zinc alloy die casting

Aluminum Die Casting

1. Usual material

GB: ZL102, ZL104, ZL108

ASNI: A360, A380

BS: LM1, LM2, LM9, LM20

DIN: G-AlSi12, G-AlSi10Mg, G-AlSi12

JIS: ADC12

2. Application

Automotive, aviation, wireless communication, HVAC, window and door, buliding and architecture, mediacal equipment, furniture, lighting and security system parts

3. Machining

2nd process machining

4. Finishing

Shot blasting/sand blasting

Polish/brush

Powder coating/painting/anodizing

Plating: cooper/nickel/chrome/satin or glossy finish

Zinc Alloy Die Casting

1. Material: 

ZAMAK2, ZAMAK5, ZAMAK7, ZA-27

2. Application

Automotive, aviation, wireless communication, HVAC, window and door, buliding and architecture, mediacal equipment, furniture, lighting and security system parts

3. Machining

2nd process machining

4. Finishing

Shot blasting/sand blasting

Polish/brush

Powder coating/painting

Plating: cooper/nickel/chrome/imitation gold/PVD, satin or glossy finish

One of the main differences between aluminum and zinc alloys is that zinc has a lower melting temperature and requires lower pressures for casting. Zinc is considered to be the most castable of all of the commonly used alloys.

By having a lower melting temperature, this enables a zinc die to last much longer than an aluminum die. Dies are expensive, and keeping them in service longer will provide a more cost-effective approach to large volume casting projects.

In addition, zinc’s lower melting temperature allows for hot chamber casting, which is less expensive than cold chamber processes. By using the hot chamber die casting method, production speed will also be increased. Zinc is one of the toughest alloys around, and it surpasses even aluminum in its ability withstand impact.

Another advantage to using a zinc alloy over an aluminum one is that zinc is great for castings with very intricate details and thin walls. When utilizing zinc, very little machining, trimming or finishing work is needed as the lower pressure and melting point reduce the thermal shock it experiences during casting. When casting in zinc, it maintains a smoother surface when a component is ejected from a die.

In conclusion

Aluminum Alloy:

 lightweight & structural material

 resistant to corrosion

 maintan in strength at high temperatures

Zinc Alloy:

 one of the heaviest material

 excellent corrosion resistance

 provides better impact strength

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