Miniature Zinc Die Casting
High Performance Miniature Zinc Die Casting Technology
Miniature Zinc Die Casting is the solution to high strength and hardness for fabricated components, machined, stamped, and pressed. A Zinc alloy also known as Kirksite or Zamak2 the zamak family, offers the highest in strength and hardiness.
Miniature _ Zinc _ Die _ Casting
Sometimes you do need to sweat the small stuff, especially when it comes to quality engineered miniature components for your project specifications. For a reliable, adaptable process to realize small custom parts choosing to cast in zinc will provide you with tailored pieces that are in it for the long haul.What is Die Casting?
Die casting is a where pressurized melted metal is injected into a die. The liquid metal enters the die chamber through holes in a pre-set die half. The melt is directed into the cavity by passageways called runners in what’s called the ejector half (the complementary half of the die). The two pieces are clamped together by a series of pins that bolt into place. The metal, then cooling to just above its melting temperature, takes the shape rapidly to the die cast. Anther set of pins pop the die cast apart in order to eject the component.
The die castings themselves are comprised of steel alloys. They consist of two pieces to allow for the cast pieces to be taken from the die: the fixed die half and the ejector die half. Other dies have additional, removable parts, that can be inserted or withdrawn to create specific shapes in the casting. Dies cooled via air or water. This process is facilitated by holes in the die cast that let in air or where coolant can be poured through. The rapid cooling of the die allows for a quick re-cycle to pound out another round like clockwork, and over a substantial period: die casting molds like this can facilitate over 5 million casts in a lifetime.
In comparison to other manufacturing processes, die casting holds some steady advantages. It is quick, competent, and easy on the wallet, offering a wide range of shapes and pieces, and not to mention, durable. Afterwards, the likely hood of editing by machining is incredibly low, because the process maintains a consistent forbearance for even the most intricate part shapes. To top it off, castings can be easily revised with plating and/or finishing. These lightweight parts maintain the strength of an alloy because they are individual parts, adding to their stability and heat resistance.Why Zinc?
Zinc offers a combination of characteristics that give it a unique advantage in many die cast applications. These include a combination of strength, ductility, resistance to catastrophic failure, impact strength and finishing characteristics.
Miniature zinc parts can meet and exceed standard linear dimensional tolerances of +/- .002" and precision linear tolerances of +/- .0015". A substantial economic benefit of the progression is the exploitation of economical die casting tooling that in many cases yields life-of-project utility and low cost zinc parts.
Miniature zinc parts are in faster cycling, produced in multi-slide hot - compartment _ zinc _ die _ casting machines. These miniature part die casting machines have established this technology as the process of choice for complex miniature zinc precision components. While high - precision miniature _ zinc _ die _ casting is comparable to hot - compartment zinc _ die _ casting of much bigger zinc parts, it is capable of holding tighter tolerances, often with zero draft, to "net-shapes" or "as-cast" at much faster cycle times.
Such miniature zinc parts are being routinely die cast with walls as thin as 0.020" in. (0.50 mm) and hold tolerances as tight as +/-0.001" in. (0.03 mm).
Zinc or ZA8 Part quality is improved by reduced metal shrinkage and the elimination of post-die casting operations. Automated zinc part production can deliver miniature zinc part unit costs down to pennies per piece, at extremely low tooling investment. And your miniature zinc and ZA-8 die casting dies (tooling) will endure for the life of your project.Advantages of Miniature _ Zinc _ Die _ Casting, the breakdown:
Assembly operations are reduced: Entire assemblies can be cast as a single unit, eliminating the need for expensive manual assembly operations.
Less material is required: Zinc takes well to die casts while maintaining strength. This in turn allows for the design of thin wall sections resulting in lighter product and saving on materials costs. Boom.
Less Machining: also due to zinc’s accommodating nature inside of the die cast, machining can be brought to a minimum or taken out of the picture all together.
Which Translates To: -Higher Volumes