Tooling for Zinc and Aluminum Die Casting Parts

by Adhecogen

Tooling for die casting parts.
A filled mold for tooling for die casting parts.

The Zinc and Aluminum die casting process is a fast process that allows the creation of many parts in a short period of time. The machines used are rather large to mass produce these parts efficiently.

What are the parts and tools used in the Zinc and Aluminum die casting process?

Software for mold design: The software used to design molds provides high accuracy and can detect and resolve any possible failures and deficiencies in the mold creation process. At ADHECOGEN, we work hand in hand with our customers to help them design their components; we offer our customers a fully integrated service.

Molds: Molds are made of metals with a much higher melting temperature than zinc or aluminum, most of them being steel. Molds are first carved with pressure to achieve the part’s shape. Then, zinc or aluminum will be injected into the molds, creating the part quickly.

Part finishing tools and software: Part finishing is a critical part of the process; it ensures that the parts are high quality with no imperfections. Once all parts are released from the molds, we have software that analyzes all the parts to ensure they are up to standards, or if there are any existing defects, the software will recommend solutions to resolve the issue. Many defects are classified as surface imperfections and can be quickly resolved by polishing the part.

Logistics tools: We use artificial intelligence for production logistics. With it, we analyze orders, deliveries, and the production process, achieving greater efficiency. Artificial intelligence software is also used to explore the best alloy for each type of part.

Injection Pistons: Water-cooled, copper alloy injection pistons push molten zinc and aluminum through a polished steel sleeve and into mold cavities to form complex parts. Injection piston clearances range from 0.05-0.13mm, with clearances of 0.05-0.13mm between the steel sleeve’s inside diameter, and the injection piston’s outside diameter.

What materials are used in the die casting process?

The materials used in die casting must be both high temperature resistant, malleable and wear resistant. For this reason, zinc, magnesium and aluminum alloys are used.

Aluminum AC 46100: Affordable, non-corrosive, low melting point and excellent weldability.

Aluminum AC 46500: High ductility and strength-to-weight ratio. Suitable for automotive and electrical parts.

Aluminum ADC 12: High melting point, expensive and corrosion resistant.

Aluminum A383: Heat treatable, good machinability and castability.

Aluminum Al-Si8Cu3: High strength, good electrical conductivity and suitable for the aerospace industry.

Zinc Zamak 2: Low melting point, good ductility and suitable for manufacturing complex parts.

Zinc Zamak 3: Good dimensional stability, easy to machine, suitable for manufacturing gears, toys and electrical components.

Zinc Zamak 4: High melting point, ideal for manufacturing engine parts, and low coefficient of thermal expansion.

Zinc Zamak 5: Excellent impact resistance, castability and ductility.

Zinc Zamak 7: Low melting point, excellent fluidity and dimensional stability.

AZ91D Magnesium: Suitable for the automotive, aerospace and electronics industries. Good castability and strength-to-weight ratio.

Magnesium AM60B: Low density, lightweight and good stiffness.

Magnesium AS41B: Non-toxic, high melting point and excellent electrical conductivity.