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Zinc Die Casting and Pressure Die Casting for High Quality Products

Zinc die casting and pressure die casting are metal fabrication processes that allow for the efficient, high-volume production of metal components with complex geometries and tight tolerances. These die casting techniques are ideal for manufacturing small to medium sized metal parts for a variety of industries and applications.

What is Zinc Die Casting?

Zinc die casting refers specifically to the die casting process using zinc alloys as the molten metal. Zinc alloys, especially zinc alloys 3, 5, and 7, are commonly used in die casting and provide excellent castability, dimensional stability, and mechanical properties.

The zinc die casting process starts with a metal die, made of tool steel, into which molten zinc alloy is injected under high pressure. The pressure forces the molten zinc into the die cavities, where it rapidly cools and solidifies into the final casting part. The entire zinc die casting process can often be completed in less than half a minute, making it extremely efficient for high volume production.

Benefits of zinc die casting include:

- Excellent dimensional accuracy and repeatability, with tolerances as tight as 0.005 inches.
- Smooth cast surfaces that require little to no secondary machining.
- Ability to produce complex geometries with hidden holes, threads, and undercuts.
- Faster production rates and lower costs compared to other casting techniques.
- Wide range of zinc alloy properties to meet strength, ductility, thermal, and electrical requirements.

Common applications of zinc die casting parts are in the automotive, electronics, hardware, and consumer products industries. Typical zinc die cast parts include gears, pulleys, wheels, motor parts, relay cases, solenoids, and instrument housings.

What is Pressure Die Casting?

Pressure die casting is a manufacturing process in which molten metal is injected into a steel die at high pressure. It is very similar to zinc die casting, except that other alloys besides zinc can be used, such as aluminum, magnesium, and copper alloys.

The pressure die casting process forces molten metal at high velocity into reusable steel dies. The pressure can range from about 1000 to over 20000 psi depending on the alloy and part requirements. Just like zinc die casting, the high pressure allows the molten metal to completely fill the die cavity and produce castings with excellent detail and dimensional accuracy.

Pressure die cast parts have thinner wall thicknesses compared to sand and investment castings. Wall thicknesses can range from 0.02 inches to 0.25 inches while still maintaining uniform strength and quality. The smooth die surfaces also lead to smooth as-cast surfaces, reducing or eliminating secondary machining operations.

Advantages of pressure die casting:

- Fast production rates and lower part costs
- Precision tolerances and detailed part features
- Excellent mechanical properties from rapid solidification
- High productivity with minimal secondary machining
- Ability to automate production

Pressure die casting is commonly used to produce parts like automotive components, outdoor furniture, business machines, and valves and fittings. Aluminum is one of the most commonly die cast metals due to its lighter weight, ease of casting, and corrosion resistance.

Precifine - Quality Die Casting and Machining

Precifine is an ISO certified manufacturer of zinc and pressure die cast products. With over 15 years of experience, Precifine provides complete solutions from design and tooling to final precision machined components.

Precifine utilizes high pressure die casting machines with clamping forces up to 800 tons to produce complex components with reliable consistency. They can work with a range of zinc and aluminum alloys to produce quality castings to meet dimensional, strength, and cosmetic requirements.

In addition to die casting, Precifine offers CNC machining and other secondary operations required to produce finished components. This includes processes like drilling, tapping, milling, broaching, deburring, polishing, powder coating, and assembly. Performing multiple operations in-house allows better control over quality, costs, and lead times compared to outsourcing.

Precifine serves customers in diverse industries including automotive, electrical, telecom, medical, and general engineering. Their engineers work closely with customers in a collaborative approach during the design and development phase. Precifine utilizes quality control techniques like dimensional inspection, tensile testing, and salt spray testing to ensure products meet specifications throughout the production process.

Some of Precifine's die casting capabilities include:

- Zinc die casting up to 10 lbs finished weight
- Aluminum die casting up to 15 lbs finished weight
- Tolerances as tight as 0.005 inches
- Multiple die cast machines up to 800 ton clamp force
- ISO certified quality management system


Zinc die casting and pressure die casting allow for the economic production of high quality, precisely dimensioned metal components. The high production rates, close tolerances, and excellent repeatability make die casting ideal for many industrial applications. Precifine utilizes advanced equipment and proven quality control methods to manufacture reliable die cast products and machined components that meet customer requirements. Collaborating with an experienced die caster like Precifine early in the design phase helps ensure manufacturability and get products to market faster. CNC Milling CNC Machining