Die casting is often categorized using the heat and pressure required to inject the molten metal into the die casting mold. However, the part manufacturing process is also categorizable based on the type of material, and zinc die casting is the most common in terms of part strength.    This article talks about die-casting using zinc, its application, and its comparison with other materials. 

Zinc die casting is a process that involves melting zinc alloys (hence the name zinc alloy die casting) and injecting it into an already prepared die casting mold.

Zinc alloys are applicable in part manufacturing due to their ductility, impact strength, and low melting point. Furthermore, the casting process occurs under lower heat due to the material’s low melting point. Hence the name “hot chamber die casting process.”

Moreover, being a hot chamber process also promote the die’s longevity, time needed before retooling, and reduction in cost compared to other materials compatible with die casting.

Steps of the Zinc Die Casting Process

Generally, zinc alloy die casting is a hot chamber die casting process.    While there are alterations in the process based on part size and machine types, there is also a general mechanism, as highlighted below:

Step #1: Preparing the Die

Clean the die-cast mold to remove impurities.    Afterward, lubricate the die for better ejection of the casted part after cooling.    Conclude step one by clamping the die with high pressure.

Step #2: Injection

Melt the zinc alloy and pour it into the injection machine’s shot chamber.    Note that the shot chamber will be hot, as zinc casting is a hot chamber die casting.  Afterward, inject the molten zinc material into the die-cast mold at high pressure.

Step #3: Cooling and Ejection

Allow the zinc to cool in the die-cast mold to take the mold shape.    Unclamp the mold to eject the solid zinc casting out of the die.

Note: Ensure the casting cools and solidifies before ejection.

Step #4: Trimming

Alongside other finishing processes, trimming involves the removal of the excess metals that occurs due to die casting defects.    Trimming is achievable using a trim die, saw, or other procedures.