Zinc die casting and aluminum die casting are two of the most widely used metal-forming processes, each dominating distinct niches in manufacturing. While both rely on high pressure to inject molten metal into molds, their differences in material properties, Требования к процессу, and end-product performance make them suited for entirely different applications—from tiny precision electronics parts to large automotive structural components. Но что именно выделяет их? How do these differences impact cost, эффективность, и качество частично? And how do you choose the right process for your project? This article answers these questions with detailed comparisons and actionable insights.
1. Material Basis: Core Properties That Define Performance
The fundamental difference between the two processes lies in their base materials—zinc alloys and aluminum alloys—whose unique traits shape every aspect of die casting. The table below breaks down their key properties:
| Материальное свойство | Цинковые сплавы (НАПРИМЕР., Нагрузки 3, Нагрузки 5) | Алюминиевые сплавы (НАПРИМЕР., ADC12, ADC10) |
| Композиция | Zinc-based, with added aluminum (3.5–4.3%), медь (0.75–1,25%), and magnesium (0.03–0,08%) | Aluminum-based, with silicon (9.5–12%), медь (1.5–3.5%), и железо (≤1.3%) |
| Точка плавления | Низкий (380–420 ° C.) | Высокий (680–720°C) |
| Плотность | Высокий (6.6–6.8 g/cm³) | Низкий (2.7 G/CM³)—1/2.5 that of zinc |
| Предел прочности | Умеренный (280–320 МПа) | Выше (300–350 MPa for heat-treated grades) |
| Пластичность | Отличный (удлинение: 10–15%)—resists impact without cracking | Хороший (удлинение: 2–5% for non-heat-treated; до 10% for heat-treated) |
| Теплопроводность | Низкий (105–115 W/m·K) | Высокий (120–150 W/m·K)—better for heat-dissipating parts |
| Surface Treatment Adaptability | Outstanding—ideal for electroplating, хромирование, and high-gloss painting | Moderate—challenged by porosity; best for anodizing, Порошковое покрытие, or baking paint |
2. Параметры процесса: Оборудование, Эффективность, and Control
Material properties directly influence process requirements—from the type of die casting machine to production speed and defect risks.
А. Выбор оборудования & Настраивать
| Process Aspect | Цинк умирает | Алюминиевое литье |
| Тип машины | Использование hot chamber die casting machines—the injection chamber is permanently immersed in molten zinc. This eliminates the need for separate metal feeding steps. | Использование cold chamber die casting machines—molten aluminum is poured into a separate injection chamber (to avoid melting the machine components). |
| Clamping Force | Ниже (50–200 tons)—sufficient for small, тонкостенные детали. | Выше (200–1,200 tons)—needed to handle high-pressure filling of large, сложные части. |
| Материал плесени | Can use lower-cost H13 steel—low melting point reduces mold wear. | Requires heat-resistant mold materials (НАПРИМЕР., H13 steel with nitriding treatment)—high temperatures demand better durability. |
| Mold Preheating Requirement | Высокий (150–200 ° C.)—prevents cold isolation defects (molten zinc solidifying too quickly on cold mold surfaces). | Умеренный (200–250 ° C.)—balances heat retention and rapid solidification for large parts. |
Беременный. Эффективность производства & Расходы
| Efficiency Metric | Цинк умирает | Алюминиевое литье |
| Время цикла | Быстрый (15–30 seconds per part)—low melting point speeds up solidification. | Помедленнее (30–60 секунд на часть)—higher melting point requires longer cooling. |
| Использование материалов | Высокий (90–95%)—minimal scrap from runners and gates (easily recyclable). | Умеренный (80–85%)—more scrap from porosity defects and larger runners. |
| Стоимость за участие (Небольшие части) | Ниже (\(0.1- )0.5 за часть)—fast cycles and low energy use reduce costs. | Выше (\(0.3- )1.0 за часть)—slower cycles and higher energy consumption increase costs. |
| Energy Consumption | Низкий (30–50 kWh per 100 части)—no need to reheat metal for each cycle. | Высокий (80–120 kWh per 100 части)—requires continuous heating of aluminum to high temperatures. |
3. Product Performance: Качество, Долговечность, and Application Fit
The choice between zinc and aluminum die casting often comes down to the part’s required performance—whether it needs to be lightweight, воздействие, or visually appealing.
А. Частичные характеристики & Ограничения
| Part Trait | Цинк умирает | Алюминиевое литье |
| Size Range | Ideal for small parts (0.1–500g)-Например., electronic connector housings, toy wheels. | Suited for large parts (500g–10kg)-Например., Автомобильные блоки двигателя, ЭВ -аккумулятор. |
| Толщина стены | Excels at ultra-thin walls (0.5–2 мм)—low melting point ensures uniform filling. | Handles thicker walls (2–10 мм)—better for structural parts but struggles with <1ММ толщина. |
| Точность | Высокий (терпимость: ± 0,05 мм)—excellent for parts requiring tight fits (НАПРИМЕР., смотреть компоненты). | Хороший (терпимость: ± 0,1 мм)—sufficient for most structural parts but less precise than zinc. |
| Defect Risks | Low—minimal porosity (thanks to low melting point and slow filling). Risks include cold shuts if mold is underheated. | Higher—prone to porosity (from turbulent filling) and shrinkage (from high cooling rates). Requires vacuum casting to reduce defects. |
| Воздействие сопротивления | Superior—can withstand drops and vibrations (НАПРИМЕР., phone case hinges, door lock mechanisms). | Moderate—may crack under heavy impact; better for static load-bearing parts (НАПРИМЕР., скобки). |
Беременный. Typical Application Scenarios
The table below maps each process to its ideal industry and part types, based on performance needs:
| Промышленность | Приложения для литья цинка | Aluminum Die Casting Applications |
| Электроника | – USB connector shells- Phone button housings- Laptop hinge components- Sensor casings | – Радиаторы (Высокая теплопроводность)- 5G router frames (легкий вес)- Power adapter enclosures |
| Автомобиль | – Small functional parts (door lock mechanisms, wiper linkages)- Внутренняя отделка (high-gloss plated parts)- Разъемы | – Engine blocks and cylinder heads- Королевки передачи- Body structural parts (lightweight for EVs)- Battery pack frames |
| Потребительские товары | – High-end hardware (Кран ручки, ручки шкафа)- Toy joints and moving parts- Косметическая упаковка (plated finishes) | – Кухонная техника (Блендер базы, oven door frames)- Открытая мебель (Погода)- Luggage frames (легкий и сильный) |
| Аэрокосмическая & Медицинский | – Tiny precision parts (medical device connectors, aircraft instrument knobs) | – Легкие конструкционные детали (аэрокосмические скобки)- Medical equipment frames (коррозионная устойчивость) |
4. Selection Strategy: Как выбрать правильный процесс
To avoid costly mistakes, follow this 4-step framework to select between zinc and aluminum die casting:
Шаг 1: Define Part Requirements
- Размер & Масса: <500g → Zinc; >500g → Aluminum.
- Weight Priority: Need lightweight (НАПРИМЕР., EV parts) → Aluminum; weight not critical → Zinc.
- Воздействие сопротивления: Высокий (НАПРИМЕР., handheld devices) → Zinc; низкий (НАПРИМЕР., static brackets) → Aluminum.
Шаг 2: Evaluate Surface & Precision Needs
- High-Gloss/Plated Finish: Необходимый (НАПРИМЕР., декоративное оборудование) → Zinc; not required → Aluminum.
- Терпимость: ±0.05mm or tighter (НАПРИМЕР., Электроника) → Zinc; ±0.1mm acceptable → Aluminum.
Шаг 3: Рассмотрим объем производства
- Low-Medium Volume (<100,000 части): Цинк (lower mold costs and faster setup).
- Высокий объем (>100,000 parts): Алюминий (cost per part decreases with scale, offsetting higher initial investment).
Шаг 4: Calculate Total Cost of Ownership
- Цинк: Lower upfront costs (машина + форма) but higher material costs (denser, uses more metal per part).
- Алюминий: Higher upfront costs but lower material costs (зажигалка, uses less metal) and better long-term efficiency for large batches.
5. Yigu Technology’s Perspective on Zinc vs. Алюминиевое литье
В Yigu Technology, we see zinc and aluminum die casting as complementary tools—each solving unique customer needs. For electronics clients needing tiny, точные части (НАПРИМЕР., Разъемы USB), our hot chamber zinc die casting lines deliver 99.5% yield rates and cycle times of 18 секунды/часть. For automotive clients requiring large structural components (НАПРИМЕР., battery frames), our cold chamber aluminum lines (equipped with vacuum degassing) reduce porosity to <0.5% and meet IATF 16949 стандарты.
We’re advancing two key innovations: 1) Hybrid mold designs for zinc casting (reducing tooling costs by 30% Для небольших партий); 2) AI-driven parameter control for aluminum casting (optimizing filling speed to cut defects by 25%). Our goal is to help clients look beyond “cost alone” and choose the process that aligns with their part’s function, продолжительность жизни, and market positioning—delivering value that extends beyond production.
Часто задаваемые вопросы
- Can I use zinc die casting for heat-dissipating parts (НАПРИМЕР., Светодиодные радиаторы)?
No—zinc’s low thermal conductivity (105 W/m · k) makes it poor at transferring heat. Алюминий (120–150 W/m·K) is far better for heat-dissipating parts. Например, an aluminum LED heat sink keeps temperatures 20–30°C lower than a zinc equivalent.
- Is aluminum die casting more expensive than zinc die casting for small parts?
Yes—for parts <500глин, aluminum’s slower cycle time (30–60s vs. 15–30s for zinc) and higher energy use increase per-part costs by 30–50%. Однако, if the part needs to be lightweight (НАПРИМЕР., EV electronics), aluminum’s weight savings may offset the higher cost long-term.
- Can zinc die casting parts be heat-treated to improve strength?
No—zinc alloys do not respond well to heat treatment; it can cause brittleness or deformation. Алюминиевые сплавы (НАПРИМЕР., ADC12) can be heat-treated (НАПРИМЕР., T6 process) to increase tensile strength by 15–20%, making them better for load-bearing parts.