Die Casting
- Compatibility
- Fits standard ASTM A36/A572 and EN 10025-2 frameworks
- Material
- High-strength low-alloy (HSLA) steel with corrosion-resistant treatment
- Minimum Order
- 20 metric tons (mix-and-match sizes available)
- Warranty
- 10-year structural integrity guarantee
- Certifications
- ISO 9001
- Thickness Range
- CE
- Standard Sizes
- RoHS compliant with full mill test reports
**1. Zinc Alloy Die Casting**
* **Key Alloys:** Zamak alloys (e.g., Zamak 3, Zamak 5).
* **Properties:**
* **Excellent Fluidity:** Allows for the production of very thin walls and complex, intricate shapes with sharp details.
* **High Strength and Hardness:** Offers good mechanical properties right out of the die casting machine.
* **Smooth Surface Finish:** Easily plated, painted, or coated with minimal surface preparation.
* **Low Melting Point:** Reduces energy consumption and die wear, extending tool life.
* **Disadvantages:**
* High density (heavy compared to Al and Mg).
* Lower corrosion resistance compared to aluminum.
* **Typical Applications:** Automotive components (brackets, handles), decorative hardware, consumer electronics housings, locks, gears, and bathroom fixtures.
**2. Magnesium Alloy Die Casting**
* **Key Alloys:** AZ91D, AM60B.
* **Properties:**
* **Extremely Lightweight:** The lightest of all structural metals, with a density about 2/3 that of aluminum and 1/4 that of zinc.
* **High Strength-to-Weight Ratio:** Ideal for applications where weight reduction is critical.
* **Excellent Damping Capacity:** Absorbs vibration and noise effectively.
* **Good Machinability and EMI/RFI Shielding.**
* **Disadvantages:**
* Higher cost than aluminum.
* Can be flammable in molten state, requiring special handling and safety procedures (using SF6 or alternative cover gases).
* Generally lower corrosion resistance, often requiring protective coatings.
* **Typical Applications:** Aerospace components, laptop and camera housings, automotive steering wheels and seat frames, power tool housings, and electronic enclosures.
**3. Aluminum Alloy Die Casting**
* **Key Alloys:** A380, A383 (ADC12), A360.
* **Properties:**
* **Excellent Lightweight Characteristics:** About 1/3 the weight of zinc.
* **Good Strength and Stiffness:** Especially at high temperatures.
* **Superior Corrosion Resistance:** Forms a protective oxide layer.
* **High Thermal and Electrical Conductivity.**
* **Fully Recyclable.**
* **Disadvantages:**
* Higher melting point than zinc, requiring more energy.
* Lower fluidity than zinc, which can make casting highly complex, thin-walled parts more challenging.
* Can be more abrasive on dies, potentially leading to higher tooling maintenance costs.
* **Typical Applications:** Automotive engine blocks, transmission housings, and cylinder heads, aerospace components, heat sinks, electronic housings, robotic arms, and structural frames.
**Summary Comparison**
| Feature | Zinc Alloy | Magnesium Alloy | Aluminum Alloy |
| :--- | :--- | :--- | :--- |
| **Density (Weight)** | High (Heaviest) | **Very Low (Lightest)** | Low |
| **Strength** | High | Very High (Strength-to-Weight) | Good to High |
| **Fluidity/Castability** | **Excellent** | Good | Good |
| **Corrosion Resistance** | Fair | Fair (requires protection) | **Excellent** |
| **Cost** | Low to Moderate | High | Moderate |
| **Primary Advantage** | Complexity & Surface Finish | **Lightweight & Damping** | Lightweight & Corrosion Resistance |
In conclusion, the choice between zinc, magnesium, and aluminum for a die-cast component depends on the specific application requirements, prioritizing factors such as **weight, strength, complexity, corrosion resistance, and cost.**
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