Zinc is a unique material mainly due to its versatile features as well as the cost reduction involved. It is best suited for use in the automobile industry because of its minimization of production costs, resistance, service life, and hardness qualities.
Automotive parts are subjected to extreme levels of stress and temperature. Zinc being a material with a mix of strength, rigidity, and hardness is therefore ideal for manufacturing vehicle components. Moreover, its lower production cost is a boon for the die casting industry along with the ability to obtain thin walls, which is less prevalent in aluminum.
Described below are some of the major advantages of zinc alloys that make it the ideal material for the automotive sector.
Energy Savings
One of the ways that zinc alloys allow cost reduction is through the energy consumed. Zinc with its lower melting temperature thereby needs minimum energy for the process of smelting and casting of the product. Compared to aluminum, the melting point of zinc is 410/420 degree Celsius that will significantly save the energy as well as maintaining the life span of the mold.
Any instances of thermic shock are reduced due to the lower temperatures that will also minimize the wear and tear that occur on the mold. Moreover, zinc has minimum impact to the environment, as it does not cause pollution or generate toxic substances.
Production Costs
The molds used in zinc die casting have a limited life span than aluminum die castings. The absence of maintenance while used in several castings and the complete production cycle can result in severely affecting the overall costs. The machining process is also eliminated in zinc die casting thereby requiring only lesser amount of operations after the product is ejected from the die.
Surface Treatments
The other key advantage of die cast zinc is its ability to be subjected to various surface treatments options. This includes galvanic chroming, zinc plating, painting, gilding, and silver plating. These finishing methods are much easier to use on the zinc alloys in the automotive industry rather than aluminum. By such treatments, the components are offered with an aesthetic finish and require minimal preparatory work.
Casting Precision
Using zinc die casting accounts for high levels of tolerances in the process than most other materials. For other materials, the same precision in the casting would require high production costs. Zinc provides the ability to craft out small and light components at reduced costs.