The decision to use die-cast zinc or die-casting aluminum depends on what your project needs. MORELUX has more than 20 years of experience making custom die-cast zinc parts. Die-cast zinc is strong. It has a smooth surface. It also resists corrosion very well. Die-casting aluminum is lighter. People often use it in aerospace or lighting die casting. The table below shows some main differences:
Property | Die-Cast Zinc | Die-Casting Aluminum |
|---|---|---|
Density | Heavier, stronger | Lighter |
Melting Point | Lower | Higher |
Corrosion Resistance | Excellent | Less resistant |
Surface Finish | Smoother | May need extra finishing |
Key Takeaways
Zinc die casting is tough and does not rust easily. This makes it good for parts that need to be strong and exact. Aluminum die casting is light and great for things that need to lose heat, like cars and planes. Zinc molds last much longer than aluminum molds. This means making things with zinc costs less over time. You should pick the right material for your project. Zinc works best for small, strong parts. Aluminum is better for things that need to be light. Both materials can be used again. Zinc die casting uses less energy, which helps the environment.
Material Properties
Die-Cast Zinc Strength
Die-cast zinc is very strong. Zinc alloys can handle hard hits and last long. Zinc die casting is strong for its weight. Many industries use zinc because of this. The table below shows how strong zinc and aluminum alloys are:
Material Type | Yield Strength (MPa) | Ultimate Tensile Strength (MPa) |
|---|---|---|
Zinc Die Casting Alloys | 2.5 times higher than Aluminum | Higher than standard Aluminum alloys |
ZA-8 | N/A | 374 |
ZA-27 | N/A | 426 |
Zinc die casting parts do not bend easily. These features make zinc good for parts that need to be tough and exact. Many makers pick zinc die casting for parts that must stay strong for years.
Aluminum Die Casting Weight
Aluminum die casting makes light parts for many uses. Aluminum is lighter than zinc. This helps when you want to make things weigh less. The table below shows how dense and tough zinc and aluminum are:
Material | Density (g/cm³) | Melting Point (°F) | Impact Resistance | Suitability for Lightweight Fabrications |
|---|---|---|---|---|
Zinc | 7.33 | 787 | Higher | Unsuitable |
Aluminum | 2.7 | 1220 | Lower | Suitable |
Aluminum die casting is strong for its weight. This helps makers build parts for cars, planes, and electronics.
Corrosion Resistance
Corrosion resistance is important for zinc and aluminum die casting. Zinc alloys fight rust better in tough places.
Material | Location | Type of atmosphere | Corrosion micron/yr |
|---|---|---|---|
High purity zinc | Wakefield.Yorkshire.UK | industrial | 6.00 |
High purity zinc | New York. USA | industrial | 7.00 |
Diecast zinc alloy | New York. USA | industrial | 6.00 |
High purity zinc | Euston, London.UK | industrial | 10.00 |
Zinc die casting parts do not rust as fast as aluminum. This helps products last longer and stay good.
Thermal Conductivity
Aluminum die casting moves heat very well. Aluminum alloys spread heat fast. This is good for heat sinks and electronics.
Alloy Type | Thermal Conductivity (W/m-K) |
|---|---|
A380.0 Aluminum | 96 |
319 Aluminum | 109 |
380 Aluminum | 96 |
Aluminum (general) | 237 |
Aluminum die casting looks nice and handles heat well. Zinc die casting is good for detailed shapes and fights rust. Each material has special features for different jobs.
Manufacturing Factors
Zinc Die Casting Process
Zinc die casting uses less heat. This saves energy and makes things faster. Zinc melts at about 420°C (788°F). Aluminum needs much more heat to melt. The table below shows how much heat and energy each metal needs:
Metal | Melting Point (°C) | Energy Consumption |
|---|---|---|
Zinc | 380–420 | Lower |
Aluminum | ~700 | Higher |
MORELUX uses new zinc die casting methods. Their process makes strong parts with tiny details. Zinc alloys help make shapes that are hard to create. The low melting point helps molds last longer.
Aluminum Die Casting Process
Aluminum die casting uses higher heat. Aluminum melts at about 700°C. This process is good for parts that need to handle heat. Makers use aluminum die casting for light parts in cars and electronics. New machines use servo controls and vacuum filling. These help make aluminum parts stronger and better.
Tooling Life
Tooling life means how many times you can use a mold. Zinc die casting molds last much longer than aluminum ones. The table below shows how many times each mold can be used:
Material | Average Tooling Life |
|---|---|
Zinc Die Casting | 1,000,000+ cycles |
Aluminum Die Casting | 80,000 to 150,000 cycles |
Longer tooling life means you spend less money. It also means less time fixing or changing molds. MORELUX’s zinc die casting helps companies save money for a long time.
Surface Finishes
Both zinc and aluminum die casting parts can look different. Some common finishes are:
Anodizing
Powder coating
Chromate conversion coating
Electrophoretic painting
MORELUX offers special finishes like polishing and electroplating. These finishes make parts look nice and protect them. Zinc die casting is great for fancy and detailed designs.
Tip: Picking the best surface finish helps parts last longer and look nicer.
Applications
Automotive & Industrial Uses
Car and factory makers use zinc die casting and aluminum die casting. Zinc die casting makes strong parts for inside and working systems. Aluminum die casting is good for light engine and frame parts. The table below shows which industries use each material most:
Material | Industries Using It |
|---|---|
Zinc Die Castings | Automotive, Medical Supply |
Aluminum Die Castings | Electronics, Communications Equipment, Automotive Components, Construction, Furniture |
Many car companies pick zinc die casting for sunroof parts and seat belt parts. They also use it for climate control pieces. These need to be tough and have exact shapes. Aluminum die casting is used for engine blocks and transmission cases. It is also used for brake parts. These help cars stay light and strong.
Electronics & Small Parts
Electronics and small gadgets need parts that fit very well. Zinc die casting is great for making connectors and housings. It also makes small working parts. These protect electronics and help them work right. Aluminum die casting is used for heat sinks and frames. These jobs need good cooling and strong support.
Connectors and housings
Enclosures for protection
Heat sinks for cooling
Chassis and mounting plates
EMI shielding components
Small, complex parts for precision
MORELUX makes zinc die casting parts for electronics. These include bezels, brackets, and cable glands. These parts are accurate and last a long time.
Outdoor & Harsh Environments
Outdoor places and tough jobs need materials that fight rust and last long. Aluminum die casting does not rust easily. It is good for outdoor furniture and building parts. It is also used for car parts that stay outside. Zinc die casting is strong and can take hard hits. It works well outside, but aluminum is better in wet or salty places.
Metal | Durability Characteristics | Natural Corrosion Resistance |
|---|---|---|
Zinc | Good strength and impact resistance | Good |
Aluminum | Superior corrosion resistance and durability | Excellent |
Note: MORELUX’s zinc die casting parts work well in tough places. They give strong and steady results for outdoor and factory uses.
Cost Analysis
Production Costs
Production costs are important when picking zinc or aluminum die casting. Zinc melts at a lower temperature than aluminum. Factories use less energy to make zinc parts. Zinc cools quickly, so the process is faster. Molds for zinc last longer. Companies do not need to replace molds often. The table below shows some main differences:
Aspect | Zinc Die Casting | Aluminum Die Casting |
|---|---|---|
Melting Temperature | Lower than aluminum | Higher than zinc |
Tooling Life | Up to 10 times longer | Shorter than zinc |
Cycle Times | Much faster | Slower |
Energy Costs | Lower | Not specified |
Zinc die casting helps save energy. It also makes recycling easier. This keeps costs low and helps the environment.
Long-Term Value
Long-term value is important for many companies. Zinc die casting molds last longer. Zinc melts at a lower temperature. This means tools do not wear out fast. Companies spend less money fixing and replacing tools. Zinc parts are strong and resist rust. They work well in tough places. They need less care over time.
Zinc die casting molds last longer, so maintenance costs go down.
Zinc parts stay strong and do not rust, so they last longer outside.
Companies save money because they do not need new parts often.
Zinc die casting is good for the planet. It uses less energy and makes fewer greenhouse gases. Studies show zinc die casting is better for the earth than aluminum die casting. Zinc can be recycled easily. This helps companies meet green goals.
Material | Recyclability Rate |
|---|---|
Aluminum | Nearly 75% |
Zinc Alloys | Energy-efficient recycling processes |
Note: Picking zinc die casting can help companies save money and protect the planet for a long time.
Decision Guide
Picking the right material depends on many things. Each choice has its own strengths. This guide helps you know when to use zinc die casting or aluminum die casting.
When to Choose Die-Cast Zinc
Die-cast zinc is best for parts that need fine details. Makers pick zinc for small and complex pieces. Zinc gives a smooth finish and quick production. Zinc molds last longer, so costs go down over time. Zinc is heavier, so it works well when weight does not matter. It does well in normal temperatures and fights rust.
Common scenarios for choosing die-cast zinc:
Small parts with tricky shapes
Products that need exact sizes
Uses where a smooth finish matters
Big production runs that need strong molds
Hardware like locks, hinges, and brackets
Tip: Zinc die casting is great for fast making, high accuracy, and molds that last a long time.
When to Choose Aluminum Die Casting
Aluminum die casting is good for light and strong parts. Aluminum works well in hot places and spreads heat fast. Makers use aluminum for big parts and pieces that carry heavy loads. Aluminum does not rust easily, so it is good for outdoor and water uses.
Aluminum die casting is recommended for:
Car and plane parts that need less weight
Engine and aircraft pieces that need to be strong
Products that need to lose heat, like radiators and electronics
Outdoor furniture and building parts for tough weather
Parts that must work well in high heat
Note: Aluminum die casting is smart for jobs that need strength, light weight, and toughness in hard places.
Quick Reference Table
The table below shows the main points for both materials. It compares how they work, how they are made, what they are used for, and cost.
Decision Factor | Zinc Die Casting | Aluminum Die Casting |
|---|---|---|
Precision | High precision and intricate details | Moderate precision |
Tool Life | Extended tool life | Shorter tool life |
Surface Finish | Superior surface finish | Good surface finish |
Production Cycle | Fast production cycles | Slower production cycles |
Weight | Heavier than aluminum | Lightweight |
Temperature Resistance | Moderate | High-temperature environments |
Structural Components | Not ideal for large components | Suitable for large structural components |
Cost Efficiency | Higher production costs | Cost-effective for large volumes |
Thermal Conductivity | Suitable for controlled heat dissipation | Ideal for electrical applications |
Minimum Wall Thickness | Can achieve 0.25 mm | Typically requires 1.5 mm |
Achievable Tolerance | ±0.02 mm | ±0.05 mm |
Applications | Hardware components (locks, hinges) | Automotive and aerospace applications |
Callout: Always think about what the part needs, where it will be used, and how many you need before you choose.
Picking zinc die casting or aluminum die casting depends on what your project needs. Zinc alloys are strong and tough. They can also make parts with exact details. Aluminum is good for parts that need to be light and not rust. MORELUX says zinc die casting is best for jobs that need to be accurate and last a long time. This includes cars, electronics, and medical devices.
To get the best results, look at your design needs and ask MORELUX for help choosing the right material.