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The following article was published in our article directory on July 31, 2013.
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Identifying and Preventing Flaws in Zinc Die Casting Parts

Article Category: Automotive

Author Name: DieCastingZinc

The requirment for precision cannot be overemphasized in zinc parts die casting manufacturing. Zinc alloy parts have to be adequate in the areas of volume, weight, strength, bearing, and ductility in order for those parts to effectively perform the functions for which they were originally designed. Even a trivial discrepancy in any of the precarious areas will result in loss of function. That would seem insignificant until you consider the fact that zinc is responsible for many of the attributes that place metal alloys among the crucial components in the construction of motor vehicles, household appliances, personal gadgets, industrial machinery, and children's toys among other essential items. Unless defects resulting from die casting zinc parts are contained and minimized, it could very well mean daily life slowing down, or perhaps coming to a complete standstill, for many people.

However, the biggest problem with zinc parts die casting manufacturing is that defects often become plain in the finished products themselves and not during the critical time as they are being made wherein defects could have been identified and resolved most effectively. Although zinc die casting is among the least expensive techniques of producing truly hard metal alloys (partly because of the huge availability of zinc and the speed at which parts are churned out), complete bundles of rejected parts could mean lost sales for any manufacturing company. This can be remedied post-production as zinc is one of the most easily environmental metals, but the time and effort spent in giving new life to rejected parts could have been devoted to creating parts that are free of defects from the very beginning.

It is extremely recommended for a zinc die casting company to consider these factors that could affect the quality of their output.

Zinc alloys such as ACuZinc, ZAMAK, and ZA alloys are the combination of zinc and other metallic elements, specifically aluminum, magnesium, and copper. Each of these alloys has a exact ratio of the metal components that must be maintained at all times. Even a small surplus in any of the non-zinc elements will lead to the alloy's deficiency in the critical areas of strength, bearing, and ductility (i.e., attributes brought about by the zinc content).

Also, therefore, timing is everything in zinc parts die casting manufacturing. A alteration of a few seconds, particularly in the transfer of molten zinc ingots from the furnace to the cast, can translate into unwanted bumps and impressions in the alloy's finish.

Furthermore, the die casting tooling utilized may be detrimental to alloy production even if melting and casting are done as exactly as possible. The tooling involved in hot chamber zinc die casting is characteristically highly tolerant with wonderful capacity (up to 15 cycles per minute in the case of miniature zinc parts), and the fact that zinc has a comparatively low melting point makes the machinery's job easier. Unfortunately, it doesn't mean the tooling itself will be devoid of defects. Regular thorough inspection of tooling and all associated equipment is therefore a must to closely identify discrepancies. A laboratory inspection may be necessary if it is suspected that defects are caused by the tooling's own chemical composition.

Although the melting and casting processes are done severely by the numbers and the die cast tooling adheres to industry standards, defects could still arise from the actual handling of the finished alloys. As the alloys are almost always in a delicate state, great care must be taken when ejecting these from the cast either by hand, by robotic arm, or by conveyor belt.

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