Die-cast Zinc Vs Aluminium castings

[roozle]

Can anyone advise me what problems I may encounter if I change from a zinc die-casting to an aluminium one. This is based on the existing casting tool being worn and I can introduce a big cost saving using aluminium.

I understand I may need to increase rib thickness in certain areas.

Any help would be appreicated.

Thanks,


Highest Regards,
Roozle

 

[swall]

If you change to an aluminum diecast alloy such as 380 that has good castability and good strength, I can't envision any problems, unless your product attributes require the higher density of zinc or you are making sacrificial anodes.

 

[CoryPad]

In general, when comparing zinc to aluminium die casting:

Al alloys require thicker walls, larger draft, and higher tolerances; also, they will have reduced die life. All of this is essentially due to the higher melt temperature of the Al alloys.

With modern design and manufacturing, the actual differences won't be very much.

Regards,

Cory

Please see FAQ731-376 for tips on how to make the best use of Eng-Tips Fora.

 

[TVP]

I agree with the previous comments. Hot-chamber die casting using zinc can produce some very thin walls that are more difficult when using aluminum, but this may not be a problem when you factor in the density difference.