Zinc Die Casting: A Prediction for the Near Future

It is possible to solidify liquid metal by injecting it under pressure into a mold.


It is possible to solidify liquid metal by injecting it under pressure into a mold, which is typically made of special steel, and then waiting for it to solidify. This process is known as die casting or "high pressure die casting" (HPDC). The casting and the sprue are then removed from the mold, and the process is repeated to complete the cycle. Die casting is the most efficient method of converting fluid metal into a finished cast part. Die-casting is used in almost all manufacturing fields that require non-ferrous metal components, such as automobiles, motorcycles, household appliances, electric engines, radio-televisions, computers, and other electronic devices, among other things.

Die casting can be divided into two categories: cold chamber die-casting and hot chamber die-casting. Cold chamber die-casting is the more common type of die casting. The cold chamber process involves pouring the appropriate amount of liquid metal into a chamber outside of the crucible, which is where the metal is located. The hot chamber process, on the other hand, involves immersing the pressure chamber in the crucible during the heating process.

Zinc Die Casting: A Prediction for the Near Future

The die casting process used today is significantly different from that used just a few decades ago. Process control systems have advanced to the point where they can be managed directly on the machine or even remotely, taking over the activities and solutions that were previously in the hands of operators with their own knowledge and skill set.

As a result of technological advancement, die-casting machines are now available that are equipped with sophisticated systems for controlling the primary parameters of die casting services (such as pressures, temperatures, metal and drive speeds, compression and cooling times). Die-casting machines are evolving in tandem with advanced design systems, which is a natural progression. In order to achieve the most optimal product structures through finite element analysis, increasingly complex shapes and tight tolerances must be produced. This is only possible with cutting-edge equipment, which is not always available.

When it comes to process design and planning, as well as when it comes to solving production and quality problems, a scientific approach is essential. As a result, Bruschi has been outfitted with a simulation program for quite some time. The program allows for an in-depth analysis of cavity filling as well as a verification of the production cycles in order to ensure that the injection points are correctly identified and that any potentially low-quality areas of the castings are eliminated.

Bruschi developed and built its own under vacuum die casting system in the 1980s (which is still uncommon today for zinc alloy die casting). Achieving blowhole-free castings while using vacuum die casting allows you to ensure compliance with both mechanical strength and aesthetic requirements while reducing costs and time spent on the job.

Zinc alloy die-casting has a variety of applications that are often overlooked. However, today's application of appropriate design procedures and process control, combined with the degree of refinement of the alloys, allows for the achievement of unexpected results in terms of product quality and production cost reduction. This is an important aspect to incorporate into new projects during the initial stages, particularly during the co-design process with the customer. With high technical content, it is possible to achieve a high degree of accuracy in the manufacturing process of the components. Because of current knowledge and current process control capabilities, it is possible to produce goods that are more accurate than those that are typically known and reported in reference standards.

An additional critical parameter that must be maintained under control during the die casting process is temperature. With the help of the simulation program, it is possible to perform a thorough analysis of the mold's thermal balance. This provides the opportunity to identify and correct issues that may arise during the production of castings with extremely thin wall thicknesses. Another important goal that can be achieved through the die casting process is a reduction in casting weight while maintaining the required structural resistance. Die casting is a process that can achieve this goal.

When it comes to painting or galvanizing parts, the study of the flows and the definition of the feeding channels, as well as the injection and overflow positions, are critical to achieving the required surface quality. An adequate surface treatment is required in almost all of the products for each sector, both for reasons of protection and for reasons of aesthetics. For die casting processes to run reliably and consistently throughout their entire life cycle, it is critical to understand the criticalities of surface treatments and to identify suitable solutions for these criticalities.

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