The choice of material in die casting is a decision that affects the quality, durability, and cost of the produced parts. Both zinc and aluminium are popular options; however, zamak offers a series of advantages that make it a superior choice in many industrial applications.
At Jegan, we delve into the main reasons for choosing zamak die casting over aluminium, such as its ability to produce thin walls, tool longevity, precision in tolerances, and material strength.
Strength and precision: keys to quality
Precision is a determining factor in which zamak stands out over aluminium. Zamak parts can be manufactured with tighter tolerances without additional processing, saving time and costs in production. This precision means the finished parts require fewer post-production adjustments, allowing smoother integration into assemblies and final products.
In addition to precision, zamak is known for its greater strength and durability than aluminium. This material offers a combination of high strength, better elongation at break, and higher hardness, making it ideal for applications that require robust and durable components. For example, in the automotive industry, where parts are subjected to high stress and wear, zamak provides a competitive advantage by ensuring that components remain functional and safe for extended periods.
Zamak’s flow behaviour is also superior, allowing for the reliable implementation of complex parts. This behaviour facilitates the creation of more detailed designs, which is essential in industries where precision and product aesthetics are critical. Zamak’s ability to flow and fill complex moulds ensures that even the most intricate designs can be produced with high fidelity.
In addition to these technical advantages, zamak has a higher density than aluminium, which adds weight to the parts – something that can be desirable in applications requiring more excellent stability. However, it is essential to balance this characteristic with the application's specific requirements, as lightweight components are critical in some industries, such as aerospace.
Capability to manufacture detailed and durable parts
Another significant benefit of zamak die casting is its ability to manufacture parts with thin walls. This process allows the production of walls with thicknesses starting from 0.3 mm. This is a precious characteristic in manufacturing lightweight and detailed components, where every millimetre of material counts. Creating these thin parts without compromising structural integrity offers designers and manufacturers significant flexibility in creating more innovative and efficient products.
Moreover, the moulds used for zamak casting have a considerably longer lifespan than those employed in aluminium casting. A zamak mould is estimated to withstand between 1 and 2 million injections (1 million is standard) before requiring replacement. This durability is between 4 to 10 times greater than that of aluminium moulds, significantly reducing long-term production costs. Manufacturers can, therefore, invest in fewer moulds and keep production running longer without costly interruptions.
Jegan, zamak die casting
The choice between zamak and aluminium in die casting largely depends on the application's specific needs. At Jegan, we offer die-casting solutions for projects across various sectors. As specialists in zamak casting, a zinc alloy that maximises the benefits of this material, we are convinced that its properties allow for more efficient, precise, and durable production. We are available to answer your questions.
Contact us to explore the possibilities, and follow us on LinkedIn to learn more about die casting and everything Jegan can do for your business.
