Zinc Die Casting vs Aluminum Die Casting
There are various materials you can use for the die casting process. Zinc and aluminum are the most common materials manufacturers will use in their parts production. Both zinc and aluminum offer different benefits, and you can use them in various applications. So, what are the differences between zinc die casting and aluminum die casting? In this guide, you will learn about the differences between zinc die casting and aluminum die casting by looking at various aspects of these casting processes.
Basic Information about Zinc Die Casting
Zinc die casting is the die casting process that uses zinc alloys as the primary materials. Manufacturers will use high pressure and high temperature in the hot chamber die casting process to turn the zinc alloys into molten zinc. Then, the manufacturers will pour the molten zinc alloys into the mold cavities to produce the parts and components for various industrial applications.
With zinc die casting, manufacturers can save a lot of money on the raw material purchase and the rapid tooling process. This process will produce parts and components with high accuracy and high dimensional stability. Also, the completed parts and components will have high thermal and electrical conductivity.
Basic Information about Aluminum Die Casting
Aluminum die casting is the die casting process that uses aluminum alloys as the basic materials, with corrosion resistance being one of its many benefits. With aluminum die casting, you can create parts and components with high dimensional stability and complex geometries, and the completed products will not rust, which is best for long-term use.
Aluminum die casting will use the cold chamber casting process, which will require a higher pressure to deliver the molten aluminum alloys into the mold cavities. This die casting process can be used as rapid manufacturing process, it will also allow you to produce high-volume parts in a shorter period, increasing the efficiency of the production process.
Zinc Die Casting Pros and Cons
Pros
1. Thermal and electrical conductivity.
2. Affordable production process, including material and tooling costs.
3. Durable, high precision, and high dimensional stability.
4. You can join different zinc parts with ease.
5. You can recycle the zinc parts when you no longer use them.
6. It is resistant to corrosion as sheet metalwork.
Cons
1. Zinc parts and components can weigh a lot, so it will not be suitable to use zinc to create lightweight parts and components.
2. The temperatures need to be put in the right way, as hotter temperatures will decrease the zinc material’s durability.
3. Zinc can be resistant to corrosion, but the corrosion resistance property will decrease when you mix other materials with it.
Aluminum Die Casting Pros and Cons
Pros
1. You can create lightweight parts and components with aluminum die casting.
2. Aluminum has an excellent corrosion resistance property.
3. You can create parts and components with complex geometries and precise accuracy.
4. You can reuse the waste materials.
5. Aluminum parts are suitable for various surface finishing applications.
Cons
1. The initial costs to prepare the aluminum die casting equipment are high, including the tooling costs.
2. Aluminum materials are lightweight, which can be quite weak when compared to steel and other materials.
3. Porosity can happen during the aluminum die casting process.
4. You will need to use aluminum die casting to produce high-volume parts and components, otherwise it will be too expensive for you to run this process.
Differences between Zinc Die Casting and Aluminum Die Casting
You can use zinc and aluminum for the die casting process, but the way you perform the die casting process will differ. Also, aluminum die casting might offer many advantages over zinc die casting, but it is often more expensive to run when compared to zinc die casting. Here are the differences between zinc die casting and aluminum die casting:
Hot vs. Cold Chamber.
Zinc die casting uses the hot chamber casting process, whereas aluminum die casting uses the cold chamber casting process. The reason is that the two materials have unique properties, and the use of hot and cold chamber casting processes will ensure that you can get the best casting results.
Corrosion Resistance Property.
Zinc alloy materials have quite a good corrosion resistance property, but the corrosion resistance can decrease when you introduce other metals during the casting process. Meanwhile, aluminum alloy materials have quite an excellent corrosion resistance property, which you can enhance during the surface finishing process.
Material Weight.
Zinc alloy materials will produce weightier parts and components when compared to aluminum alloy materials. Thus, zinc die casting is not suitable for producing lightweight parts and components.
Design Complexity.
You can create much more complex parts and components using the aluminum die casting process. Aluminum alloys also have tighter tolerances, so it’s best for you to use them for producing parts that require more precision and accuracy. You can still use a complex design for zinc die casting, but aluminum die casting will allow you to use an even more complex design.
Costs.
Overall, zinc die casting can give you much more affordable costs for the overall process when compared to the aluminum die casting. Zinc alloy materials are much cheaper to purchase, and the tooling costs for zinc die casting are also quite cheap. Meanwhile, aluminum die casting might set you up for a big initial investment for the materials, tooling, and equipment.
Conclusion - Should You Use Zinc Die Casting or Aluminum Die Casting?
The answer will be up to your project requirements and the applications of the parts and components you are producing. For instance, for aluminum die casting, you can use this process to produce lightweight components and parts in a wide range of industries, such as automotive, aerospace, home appliances, electronics, and many others. Meanwhile, zinc die casting is not practical to use for producing lightweight parts. However, zinc die casting is still useful for various applications, such as plumbing, home appliances, manufacturing equipment, and many others.
So, both die casting processes have their own uses and applications, both of them can be used as die casting for industrial components, which means you can’t compare them and choose one over the other. Depending on the production goals you have, you can use either zinc die casting or aluminum die casting after weighing their pros and cons first.
Besides from zinc die casting and aluminum die casting, TEAM Rapid offers a series of services such as CNC turning, CNC milling, 3d print services, plastic injection molding service etc. for your needs. Contact us today to request a free quote now!
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