The hot work die steel materials commonly used in zinc alloy die-casting molds include T302 and SKD61, which generally have a hardness of about HRC50. Although these materials can meet general usage requirements, due to their relatively low hardness, they will gradually approach the end of their lifespan due to wear and tear during long-term use. For zinc alloy die-casting molds that require large-scale production, choosing mold steel with higher hardness is a solution. For example, VIKING steel, TS580 steel, HD steel, and YXR33, among others, have a hardness exceeding HRC54, demonstrating excellent wear resistance and effectively extending the service life of molds.

Due to the fact that the causes of each defect come from multiple different influencing factors, in actual production, to solve the problem, it is necessary to first adjust the machine in the face of numerous reasons? Should we change the materials first? Or modify the mold first? Suggest processing according to the difficulty level, starting with simplicity and then complexity, in the following order:

1. Clean the parting surface, clean the cavity, and clean the top rod; Improve coatings and spraying processes; Increase the clamping force and increase the amount of metal poured. These measures can be implemented through simple operations.

2. Adjust process parameters, injection force, injection speed, filling time, mold opening time, pouring temperature, mold temperature, etc.

3. Change materials, select high-quality aluminum alloy ingots, change the ratio of new materials to recycled materials, and improve the melting process.

4. Modify the mold, modify the pouring system, add internal gates, and add overflow grooves, exhaust grooves, etc.

For example, the reasons for the occurrence of burrs in die-casting parts are:

– Die casting machine issue: Incorrect adjustment of locking force.

– Process issue: The injection speed is too high, resulting in a high pressure shock peak.

– Mold issues: deformation, debris on the parting surface, uneven wear of inserts and sliders, insufficient strength of the template.

The sequence of measures to solve the flying edge: clean the parting surface → increase the locking force → adjust the process parameters → repair the worn parts of the mold → increase the rigidity of the mold. From easy to difficult, with each step of improvement, first verify its effectiveness, and if not, proceed to the second step.

Medical Device Zinc Die Casting leverages zinc alloy’s exceptional precision, biocompatibility, and sterilizability to produce high-performance components such as surgical instruments, imaging equipment parts, and drug delivery mechanisms. Zinc alloys like Zamak offer superior strength-to-weight ratios, corrosion resistance, and smooth surface finishes critical for medical applications requiring stringent hygiene standards (e.g., autoclave sterilization) and tight tolerances. The process enables intricate, miniaturized designs for implants or diagnostic tools while ensuring compliance with regulatory requirements (ISO 13485, FDA). With rapid production capabilities and cost efficiency for high-volume orders, zinc die casting delivers durable, lightweight, and reliable solutions tailored to the rigorous demands of the healthcare industry.

1. The cost of zinc alloy die-casting molds is relatively high

Making molds is a crucial step in zinc alloy die-casting or plastic injection molding. Zinc alloy die-casting is the rapid manufacturing and forming of zinc alloy using a die-casting machine, which requires the production of zinc alloy die-casting molds. This type of mold is composed of multiple complex components, with high production difficulty and long production cycle, resulting in relatively high costs.

2. The cost advantage of zinc alloy die-casting is gradually emerging

Although the cost of zinc alloy die-casting molds is relatively high, the cost advantage of using zinc alloy die-casting will gradually become apparent in large-scale production. Because the high cost of zinc alloy die-casting can be allocated to each product during mass production, the cost of each product is relatively low. In addition, zinc alloy has high density, strength, can be reused multiple times, and has a long service life, which can reduce investment costs.

3. Plastic injection molds have low cost but relatively high product cost

Compared to zinc alloy die-casting molds, plastic injection molds have lower costs and lower production difficulties. However, it should be noted that the cost of plastic injection molds is relatively high. Because during the injection molding process, plastic particles require heating, compression, and injection molding. In addition to mold costs, a series of equipment costs such as injection molding machines, heating equipment, and cooling water circulation also need to be considered. Therefore, when large-scale production is required, the cost of plastic injection molding may be higher.

1: Differences in conceptual definitions: Zinc alloy is an alloy composed of zinc as the base and other elements added. Common alloying elements include low-temperature zinc alloys such as aluminum, copper, magnesium, cadmium, lead, and titanium. Aluminum alloy is a general term for alloys based on aluminum, mainly containing alloying elements such as copper, silicon, magnesium, zinc, manganese, and secondary alloying elements such as nickel, iron, titanium, chromium, lithium, etc.

2: Performance differences: Zinc alloy has a low melting point, good flowability, easy fusion welding, brazing, and plastic processing, corrosion resistance in the atmosphere, and the blind material is easy to reuse and remelt; But the brittle strength is low, and it is easy to undergo size changes due to natural aging again. The hardness of zinc alloy is 65 to 140, and the tensile strength is 260 to 440. Aluminum alloy has low density but high strength, similar to or exceeding high-quality steel, good plasticity, and can be processed into various profiles. It has excellent conductivity, thermal conductivity, and corrosion resistance. The hardness of aluminum alloy is 45 to 90, and the tensile strength is 120 to 290.

3: Differences in Die Casting Processes: The melt temperature of zinc alloy die castings is over 380 degrees, while that of aluminum alloy die castings is over 600 degrees. The die-casting equipment for zinc alloy and aluminum alloy is different.

4: Difference in service life: The service life of aluminum alloy die castings is 100000, while that of zinc alloy die castings is 200000.