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Feb 18, 2022, 06:28 PM 116 read

What is zinc die casting? What will 2022 look like?


Zinc die casting is a process that involves injecting liquid metal into a mold under pressure, usually made of special steel and solidifying it. Die casting technology is the shortest way from liquid metal to finished products. It has different application fields (first, automobile, electronics, electromechanical, household appliances and generally all industries requiring non-metallic components). Iron).   In this blog post, our goal is to imagine the future trend and scenario of this process, because compared with decades ago, modern die casting has embarked on a decisive development path. When it comes to the future of zinc die castings, the opportunities provided by simulation software can not be ignored.   Numerical simulation of zinc die castings The numerical simulation of all processes can add value to die casting activities because it can shorten the time to market and optimize the testing and verification stages, resulting in significant cost savings.   Numerical simulations have usually been considered for the entire filling process (see blog post: "die casting simulation: Research on waste reduction"), but their use can be increasingly extended to the general study of die casting behavior. During the withdrawal phase or when detecting any internal tension, until any possible abnormalities in its structure and surface are analyzed.   In this way, the method of die-casting activities becomes more structured, moving from experience standard (or "experimental learning") to data-driven method, which can save costs and resources and make more informed decisions.   In addition, process and product simulation can be used as a database for the discovery of new application fields of lead-zinc die casting. For example, the simulation of thin thickness has provided useful results for various application fields and automotive fields, thanks to simulation activities, and new zinc components have been created, which may never have been born without this type of analysis.   Influence of technology on new die casting process Even at the process level, zinc die casting has important innovations, especially in brewski, all of which are closely related to the contribution of technology to operational needs.For example, in order to overcome the cavitation problem, some analysis is being carried out to minimize its impact, but the use of hydrodynamic simulation is being studied, again through software, to modify the supply channel and flow system to prevent this situation from damaging the mold.   However, with regard to the new die casting technology, an attempt to apply the hot runner injection process (usually used for plastic molding) to zinc alloy is being considered. This technology can avoid the generation of so-called "sprue" (i.e. sprue), thus reducing the process management cost associated with subsequent elimination. Failure to eliminate the heat saved by the sprue will also have important consequences from a green perspective, such as producing less carbon dioxide and more respect for the environment.   Similarly, in terms of machines, technological progress allows more and more complex systems to control the main parameters of the die casting process. It is also possible to deepen the correlation between the inlet (speed, pressure and pressure characteristics) injection profile) and the output (weight, burr, surface quality), with the help of statistical process analysis software.   Finally, we have carried out new research on the recycling of zinc alloy from zinc alloy casting waste. This type of product makes it possible to embrace the themes of circular economy, zero waste and recycling, which until a few decades ago seemed Utopian compared with the foundry world   Advantages of zinc die castings Compared with other materials (such as aluminum), zinc die casting has many advantages. The first advantage is that it is easier to manage the final surface treatment (chrome plating, painting...). This advantage associated with the use of zinc is very useful for all applications that must meet both aesthetic and functional requirements (e.g. corrosion resistance) and is increasingly in demand in the market.   In addition, zinc die casting has lower process cost because the service life of zinc alloy die is five times that of aluminum due to the higher melting temperature (650 ° compared with aluminum. Relative to about 400 ° Zamak).   Then, the cycle time of the process is much faster, because zinc can be treated in the hot chamber, while aluminum can only be treated in the cold chamber. We refer to the technical explanation of the difference between the two processes in the blog article "zinc die casting: looking forward to the future". It should be emphasized here that the hot chamber process that has been used in bruschi to produce zinc alloy parts can improve the speed of the production process and significantly reduce the machining after the die-casting stage.   Bottom line: the future of zinc die casting Market Despite the current economic situation, the die casting market shows some encouraging trends. From today to 2026, the global growth rate is estimated to be 6%, and the zinc alloy market seems to meet this requirement.   Of course, the technological progress being experienced by zinc die casting, as we said, with the increasing use of software and simulation technology, can help divert the interest of potential customers who usually turn to plastics or plastics. Aluminum market to zamac market.   Everything depends on continuous innovation. From the perspective of aesthetics and function, it can create high-quality zinc alloy die castings, which will be greatly saved from the perspective of production cost. Bruschi has an ambitious goal of standing at the forefront of the die casting Market and constantly accepting the application of new technologies and methods to daily operations to promote the development of the industry.

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