Benefits of Forged Aluminum for Many Applications

In recent widespread publicity on the increasing use of light metals in the transport sector replacing steel has however in a wide range of applications has overlooked the tried and proven technology of aluminum forging. While considering fabrication options available to the designer, it is clear that some of the emerging casting technologies deserve close examination however at low cost the characteristics of a relatively simple forged design often provide the desired weight + strength.

Surface Finish

from very sharp serrations to relatively smooth surfaces, with forging a wide range of surface finishes can be produced and this may be a functional attribute of the part design or facilitate further surface finishing. Some alloys, like 6061, without any further surface treatment at all have desirable anti-corrosion characteristics.

Cost

In applications from the functional perspective where several fabrication options are viable, cost will be a major driver. Generally forging tooling is quite cheaper, for example, high-pressure die cast tooling, and the production rate is higher. To provide desirable heat treatable characteristics, offsetting this is generally higher raw material costs, associated with the necessary alloying of raw materials. Consequently, in highly stressed applications many aluminum forging process are used, although this is not always the case.

Strength

The light (SG=2.7) and common aluminium alloys when forged and heat treated exhibit some mechanical properties that is comparable with many grades of steel. Therefore the strength to weight ratio is far superior.

Forging is always porosity free unlike some casting processes from aluminum forging manufacturer thus allowing relatively straight forward heat treatment processes that significantly improve selected mechanical characteristics. Typical values of 310MPa is attained by lower cost 6061,which is also superior to, for example, A356 (or 601 types) Al casting alloy whether that alloy is semi-solid cast, squeeze cast or gravity cast. With 6061 aluminium, further fabrication by welding is also available hence opening the opportunities for many other applications.

The Zamak die-casting is Hugely Beneficial

Zamak die casting is a beneficial process as it fully exploits the characteristics of the alloy in question, which are unique in the sector and highly performing. Zamak (Z-Zinc, A-Aluminum, MA-Magnesium, K-Copper in the German language), is in fact an alloy that mainly constitute of high purity zinc mixed with small percentages of aluminum, magnesium and copper. Zinc gets hard and resistant due to the presence of these elements.

At first it was used for decorative applications or contour pieces. By time it has been able to perform more important functions. With the other high-performance casting materials such as aluminum, magnesium and brass, the mechanical properties of Zamak are now compared. In particular, with Zamak die casting you can easily get better finishes, precise walls and ribs because it is a particularly uniform alloy, which does not need subsequent processing.

Because of the high fluidity and low melting point of the zamak ,products are obtained with minimum tolerance limits and complex shapes, which with the other alloys is difficult, if not impossible, to achieve. This is the reason why Zamak Die Casting Process is highly used and preferred to other alloys, particularly in components sectors, the furniture, hardware and clothing. In addition, compared to other processing techniques die-casting of Zamak is less expensive as a result the production costs of the pieces are lower, but to the quality of the final products this is not detrimental.

Zamak die casting and recycling

The advantages are not at all restricted to quality, but also embrace the environment. Compared to other materials Zamak die-casting from Zamak Die Casting Manufacturer has in fact a reduced impact on the atmosphere because for the transformation of the raw material into the finished product it collects less energy. Zamak is a material that lasts over time as it has an excellent resistance to wear and does not require frequent replacement, with the consequent savings in terms of disposal and processing. Furthermore, the products are completely recyclable if the die-casting of the zamak has been carried out correctly.

Know About the Benefits of Zinc Die Casting

For casting purpose zinc is one of the easiest metals, and for automotive parts zinc die casting offers numerous benefits. Zinc die casting combines a high level of production efficiency, superior quality and cost-effectiveness. Below is provided guide in using zinc die casting for automobile parts, including benefits, applications and the casting process in the industry.

Advantages of Zinc Die Casting include:

Faster die casting process: Hot chamber die casting and cold chamber die casting are the two main die casting processes. Cold chamber method is needed for aluminium die casting, which only allows for two or three shots a minute. On the other side, hot chamber die casting is used by zinc die casting, which can allow four or five shots a minute, saving you both time and money.

Maximum strength and hardness: Compared to aluminum or magnesium parts zinc parts are naturally stronger that to without any special treatment. However there are some zinc alloys that can be over twice as strong as and 15 times harder than A380 aluminum alloy.

Greater flexibility: Zinc is an extremely fluid metal. Compared to aluminium, it is easier to work and gives you more options while casting parts. With the use of Zinc Die Casting Process, you can make parts in complex shapes with thinner walls. This capability is because of the fact that aluminum is lighter in weight than zinc.

Excellent thermal and electrical conductivity: It offers good electrical conductivity, which is becoming highly important as more car systems become dependent on electronics.

High corrosion resistance: In longer run parts made with zinc that are exposed to the environment will stay looking great. As a result, for continuous maintenance you get extended die life without the need.

 

Eco-friendly and sustainable: Making products with the use of sustainable resources is more important than ever. Zinc die casting from Zinc Die Casting Manufacturer is an environmentally friendly process, and it’s quite easy to recycle zinc parts into new zinc alloys.

Better stability and finishing: Compared to other metal alloys, zinc offers a higher level of dimension stability as well as for an aesthetically appealing finished product it provides superior finishing characteristics.