Zinc Die Casting

Zinc pressure die casting is a highly efficient manufacturing process that produces precise, complex metal components by injecting molten zinc alloy into steel molds under high pressure. This process combines exceptional dimensional accuracy with excellent surface finish, making it ideal for high-volume production of intricate parts.

Back to services Contact Us

Zinc Casting: Premium Materials for Precision Manufacturing

ZL3 and ZL5 are the most commonly used high-performance zinc-based die casting alloys that deliver exceptional mechanical properties, excellent castability, and proven reliability across diverse industrial applications. Both alloys conform to EN 1774 specifications and represent the gold standard for hot chamber pressure die casting operations.

Gallery

Prototype To Volume Production In A Wide Range of Finishes

ZL3 and ZL5 zinc die casting alloys represent proven solutions for demanding manufacturing applications. ZL3 offers excellent dimensional stability and cost-effectiveness for general-purpose applications, while ZL5 provides enhanced strength and castability for more demanding requirements. Their non-sparking properties make both alloys invaluable for safety-critical applications in explosive environments.

Contact our technical team to discuss how ZL3 or ZL5 can optimise your next die casting project, ensuring the perfect balance of performance, safety, and manufacturing efficiency for your specific application requirements.

Benefits of using Zinc Cast

Superior Dimensional Stability: Maintains excellent dimensional precision in the as-cast condition, making it ideal for applications requiring tight tolerances
Excellent Castability: Flows smoothly into complex geometries and intricate details with minimal casting defects
Cost-Effective Solution: Optimal balance of performance and economy for high-volume production runs
Consistent Quality: Reliable mechanical properties ensure predictable performance across production batches
Non-sparking materials, making ZL3 and ZL5 an essential choice for applications in potentially explosive environments.
Corrosion Resistance: Good general corrosion resistance, but consider protective coatings for harsh environments.
Improved Surface Finish: ZL5 in Particular has excellent surface preparation characteristics, particularly beneficial for electroplating applications.

FAQs

High-performance zinc-based die casting alloys that deliver very good mechanical properties, excellent castability and exceptional electro-plating properties.

Yes, ZL3 & ZL5 can achieve tighter tolerances than aluminum or magnesium die casting, with typical tolerances of ±0.1mm and excellent repeatability across production runs.

Zinc die castings can be finished with a variety of options, including electroplating, powder coating, and painting. Electroplating with materials like copper, nickel, or chromium is common for decorative purposes and corrosion resistance.

Zinc generally provides better mechanical properties, including higher strength and rigidity, compared to aluminum and magnesium. It also allows for thinner walls and more intricate details. Zinc also has excellent machinability regarding milling, turning and especially tapping threads.

Zinc Alloys Characteristics

Technical Specifications

ZL3

Melting Point: Approximately 385°C (725°F) – enabling efficient hot chamber die casting
Tensile Strength: Excellent strength-to-weight ratio for structural applications
Density: 6.6 g/cm³ – providing substantial feel while remaining lightweight
Operating Temperature: Suitable for continuous operation up to 100°C under stress, 150°C for unstressed components

ZL5

Melting Point: Approximately 385°C (725°F) – optimized for hot chamber die casting
Enhanced Tensile Strength: Higher strength and hardness values than ZL3
Superior Creep Performance: Better long-term dimensional stability under sustained loads
Density: Similar to ZL3 at approximately 6.6 g/cm³
Critical Safety Advantage: Non-Sparking Properties

Zinc Die Casting Foundries UK. Aluminium Die Castings

Benefits of Zinc Diecasting?

Achieves tighter tolerances than aluminum or magnesium die casting, with typical tolerances of ±0.1mm and excellent repeatability across production runs.

Naturally smooth surface finish eliminates the need for machining in most applications. Ready for plating, painting, or powder coating immediately after casting.

Depending on the part’s mass properties, generally speaking cycle times for Zinc castings are faster than that of Aluminium and Magnesium castings. This is due to thinner wall sections that are achievable and the lower casting temperature of the molten metal, combined with thin casting wall sections.

Lower operating temperatures result in minimal die wear, with tool life often exceeding 1 million cycles for high-volume production.