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Technology Production Zinc Diecasting
PRODUCTION - ZINC DIECASTINGThe zinc diecasting process: The diecasting process is characterised by the use of a permanent mould. This means that the mould is manufactured only once for a series of identical components. Zinc diecasting involves pressing the liquid melt of a zinc alloy (known as Zamac alloys) into a diecasting mould under high pressure and extremely quickly. This process is performed according to the required surface quality and wall thickness within approximately 10 to 20 milliseconds. It produces high-precision cast parts with a high degree of hardness and strength. The achievable tolerances are in the ± 0.05 to ± 0.15 mm range, which means that it can also be referred to as precision or finished casting. Due to the relatively low melting point and a particularly narrow solidification interval of the zinc alloys, particularly narrow tolerances and precise surfaces can be achieved with zinc diecasting This allows large quantities to be produced from a single mould. Quantities can exceed 10,000 units/h in the case of small parts. The dimensional stability is around 2 million shots. The hot chamber process: Diecasting machines with a hot filling chamber incorporate as a special feature and directly in the melt, which is kept hot in a crucible, a structure that connects the furnace to the diecasting mould. The diecasting machine and the holding furnace form a single unit. The casting unit is also located in the melt. This renders the casting of aluminium-based or copper-based materials impossible, because at the higher temperatures of at least 700 °C, there is a risk of the metallic blank permanent moulds being destroyed by uncontrollable diffusion.
This process can be fully automated in industry, giving rise to rapid cycle times of three to four seconds. With this type of machine, the liquid metal is sucked in by the upwards-moving ram. During the downward movement, the inlet opening is closed and the liquid metal is pressed into the diecasting mould. The die-casting machines have a high heat dissipation speed. This makes the microstructure of the cast part very fine grained, and very dense immediately under the shell of the parts. "(Source: Wikipedia)"
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