Aesthetic advantages

Zinc alloys offer numerous aesthetic advantages, including the main one, an excellent tactile feeling which conveys a sensation of robustness and solidity to the object and is also pleasing to the eye due to its technical and technological qualities.

In addition, the design of the zinc alloy components is customizable, both through painting which offers a wide range of colors and finishes to adapt to the desired design, and through numerous galvanic treatments, such as, e.g., nickel or chrome plating, to obtain a shiny and wear-resistant appearance over time.

Functional advantages

The functions of zinc alloys in household appliances, on the other hand, are manifold. The zinc die-casting process offers a unique result in the field of alloys: providing a finished product at the first stage of its processing. That automatically translates into significant savings in terms of costs and production times.

Furthermore, the superior fluidity of zinc alloys allows for thinner thicknesses to be created (unlike other materials, especially plastics), reducing the costs of the raw materials used without renouncing the rigidity requirements of the product, which are fundamental for obtaining equally functional but with a small footprint. In addition, the dimensional stability, resistance to vibrations, and impact resistance are further advantages offered by zinc alloys, making them ideal for internal and external parts of small appliances.

The ductility of zinc alloys is another fundamental aspect of this material and brings great advantages for creating household appliances. This property, in fact, makes it possible to use riveting as an alternative fastening method to screws; reducing the machining costs required for threading and the assembly times needed for tightening the screws; no less important are the aesthetic and cost results for assemblies with rivets, which unlike screws can be hidden from view and translate into economic efficiency since fewer components are needed to create the same finished piece.

Finally, among the functional qualities of zinc alloys, we can also mention the excellent level of shielding from magnetic fields of this material, in fact preventing the electronic and electrical components from interfering with each other, compromising the product’s performance.

Environmental benefits

From an environmental point of view, zinc alloys represent an ecological, eco-sustainable, and ideal choice for a circular economy. Zinc alloy parts are totally recyclable. They can be recovered and reused countless times, helping to reduce the environmental impact of plastic waste and other non-recyclable materials. They require less energy for their transformation, which makes their use more sustainable from an energy point of view.

Economic advantages

The use of zinc alloys, unlike other die-casting alloys, undoubtedly has economic benefits in production. The transformation from solid to liquid state of zinc alloys for die-casting requires lower temperatures and therefore consumes much less energy than, for example, aluminum alloys. That also translates into a considerably longer life of the moulds. With the same use, a zinc die-casting mold can also be used for up to a million cycles without deterioration, allowing for considerable savings in production costs.
This aspect is particularly evident when considering the cost of the moulds for producing aluminum parts, which require more frequent replacements.

Practical examples

A significant example of the application of zinc alloys in small household appliances can be seen above all in the kitchen. Most manufacturers of quality household appliances use zinc or zamak alloy components to give their products solidity, stability, and aesthetic finishes.

For example, the external and internal housings of small appliances are often made of zinc alloy to guarantee a resistant and long-lasting structure. This approach is particularly evident in parts that require greater dimensional stability, such as bearing housings and internal supports of appliances.

Even the supports of electric motors are another example involving the use of zinc alloys. These components, found in many small appliances, can be made of zinc alloy instead of expensive reinforced plastics, offering a more environmentally and cost-effective solution.

Conclusions

Zinc alloys are confirmed as an excellent choice for small household appliances, offering numerous aesthetic, functional, environmental, and cost advantages. Their ability to be machined with precision, resistance to vibration and shock, total recyclability, and process cost savings make them ideal for meeting the needs of modern home appliances. Looking into our kitchens, we can appreciate how zinc alloys are successfully applied in the small household appliances sector. Choosing zinc alloys to produce parts and components means combining attractive design, reliable performance, environmental sustainability, and economic advantages.

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Characteristics of zamak

Zamak is an alloy composed of zinc, aluminum, magnesium and copper. According to the different percentages of these components the alloy has variable characteristics and can be used for the manufacturing of products for different market sectors. For an in-depth look at different types of zamak and their features, read the article ZAMAK molding in hot chamber die casting: chemical composition.

The characteristics of zamak that are particularly beneficial for the production of components for electronic products are:

Electromagnetic shielding

Zamak has good shielding properties with reference to Electromagnetic Interference (EMI). Therefore, it is especially suitable for the production of housings for electromagnetic cards because it is a product that requires a reduction of interferences

Heat dissipation

The properties of heat dissipation of zamak are similar, if not higher, to those of other materials. In this case, what makes zamak products competitive is the manufacturing cost of the product, the lifespan of the mold and the possibility to achieve products that do not need relevant secondary mechanical operations. For further information about this property of zamak, we suggest this case study: Zinc Heatsink Case Study: Loewe TV Heatsink.

Thin wall thickness and reduced dimensions

Zamak fluidity allows the achievement of a very thin wall thickness and of an extremely high level of detail in components of reduced dimensions. This is particularly important in the case of electronic products, which usually are characterized by very small dimensions and by a great number of details.

Stiffness and anti-vibration properties

These properties of zamak are especially relevant in case of electronic products employed in critical environments. In the industrial field, for example, electronic connections of some kinds of machine tools could be exposed to mechanical stress or vibration. It is evident that in cases like the one just described, zamak offers a protection and a vibration damping capacity that plastic could not offer.

To discover something more about chemical, physical and mechanical characteristics of zamak read the Zinc Association Engineering in Zinc, Today’s Answer, which contains very detailed information on these subjects.

Zamak components for electronic products: characteristics and competitive advantages

Let’s now analyze some zamak components for electronic products to examine their characteristics and competitive advantages.

Hard disk case

In this hard disk case we can observe how zamak properties contribute to the functionality of the product in several ways. Indeed, the case is anti-vibration and this allows the hard disk to work in stable conditions. Furthermore, as you can see in the picture, the product has both very small particulars and thin thickness. Specifically, directly during casting phase thanks to zamak it has been possible to realize the honeycomb grid that allows heat dissipation in the server through air circulation. With other materials the grid could have been achieved only through secondary operations, such as shearing, with unavoidable consequences in terms of timing and costs.

Housing for steering wheel lock

This housing hosts the electronic card of the steering wheel lock. In this case it is the properties of electromagnetic shielding and stiffness of zamak to make the product competitive compared with other similar products manufactured with other materials. As a matter of fact, the shielding allows the electronic card to function in optimal conditions without being subjected to the interference of near electromagnetic fields. Then, for this particular product, stiffness makes zamak especially competitive compared to plastic. Often when plastic housings are installed electronic cards tend to bend, whereas  the stiffness of zamak leads to a higher protection, thus extending its lifespan.

Device for checking, counting and separating banknotes

As far as this product is concerned, zamak has replaced stainless steel, thus cutting production costs and the need for mechanical operations and finishing. This has been made possible by the properties of zamak and especially by the capacity of the alloy to reach thin wall thickness and a high degree of detail. In this way the customer has obtained a product that does not need to be assembled, manufactured with molds with a long lifespan, which need little maintenance and with scrap rates close to zero.

Housing for corporate network connectors

The housing for corporate network connectors is illustrative of the properties of shielding, stiffness and resistance of zamak. For these kinds of products, shielding properties of zamak allow freedom to the electronic designer, who can mitigate the drawbacks linked to the electromagnetic waves without special precautions, but only through the choice of the most suitable material. Stiffness and resistance of the material make the use of the component suitable for particularly critical environments, such as production departments of a plant.

Conclusions

With this brief overview on zamak components for electronic products we have analyzed how some properties of zinc alloys allow the achievement of competitive and effective products. However, these are not the only components for the electronic industry that can be manufactured in zamak. For a more comprehensive overview visit our website www.bruschitech.com in the Services page.

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Zinc is not only a metal used for die casting: first of all it is a natural occurring element that is essential for life and it is considered a “Life Saving Commodity” by the United Nations. Zinc indeed plays a fundamental role for our planet: it is vital for the natural development of biological processes of every living thing, such as cell division, protein synthesis, immune system and growth. It is therefore an essential element for life.

Furthermore zinc is highly recyclable, when it reaches the end of its life cycle it can indeed be recycled without losing any physical property, thus representing a new source of raw material. Approximatively 45% of available zinc at the end of life cycle is recovered and recycled; in Europe and in the United States this percentage reaches even 50%.

It is exactly this characteristic that is a key element for sustainability and development of a circular economy.

Zinc contributes to circular economy

Circular economy is an economic model based on waste reduction and on the development of a circular life cycle, at the end of which a product is no more considered a waste for disposal but is instead a new source of raw material. Zinc fits perfectly in this model: zinc life cycle indeed starts from mining, goes through refining process in order to be used in the modern society and ends with recycling stage at the end of its useful life. During this cycle zinc contributes in different ways to the well-being of our planet:

• It is highly recyclable, thus reducing need for new raw material and exploitation of natural resources

• It protects steel used for infrastructures and transport from corrosion extending the life cycle of steel products

• When used for coating steel it contributes to the reduction in CO₂ emissions

The countless areas of use of zinc and its excellent physical properties therefore confirm the great importance that zinc life cycle has for our planet. Here in Bruschi we are proud to use a highly sustainable material, essential for life and for the protection of the riches of our Earth.

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Zinc alloys are an excellent material for the production of resistant, aesthetically appealing and complex shaped components: they can indeed be used to meet the requests of various and different industries, from automotive to building sector, ensuring high performance standards, both from a functional and an aesthetical point of view. Taken into account the different characteristics required by each sector it is therefore fundamental to conduct a thorough analysis of zinc alloys with the aim of identifying the most appropriate one for the purpose we would like to reach, examining the requirements of the product and looking for a zinc alloy with the right properties to meet these demands.

In order to conduct this analysis it is essential to know zinc alloys classification, which can be divided into two main categories: ZAMAK alloys, whose name is composed of the word Alloy followed by a number on the basis of their sequential development, and zinc alloys classified with the prefix ZA, which have a remarkable higher percentage of aluminum compared to the previous ones and are therefore provided with a greater resistance.

At the beginning ZAMAK was a trademark registered by New Jersey Zinc Co., the first company to use this specific alloy, but with the passing of time it has been chosen as the common name to define all zinc alloys for die casting. Only with the development of numerous types of alloys the nomenclature of zinc alloys has become more structured, as we have seen with the distinction between ZAMAK and ZA alloys: however, ZAMAK is still considered the most common and conventional name to indicate a zinc alloy.

This acronym indeed defines a zinc alloy composed of four main metals: zinc, aluminum, magnesium and copper (Kupfer in German). These elements occur in zinc alloys in different percentages: alloys indeed differ on the basis of the concentration of each metal, thus showing different characteristics that affect the features of the diecast. These characteristics are crucial for the choice of the most suitable zinc alloy for one’s own technology and production process. ZAMAK can indeed be worked with different production processes: hot chamber die casting, cold chamber die casting, spin casting, sludge casting and gravity die casting. In this article we are going to focus on the best zinc alloys for hot chamber die casting, the technology that Bruschi employs for its business.

The main zinc alloys used for hot chamber die casting are:

• Alloy 2
• Alloy 3
• Alloy 5
• ZA8

ZA8 is the only alloy, among the previous ones, that does not belong to ZAMAK classification because it contains a high quantity of aluminum that categorizes it as ZA: it is however an especially suitable alloy for hot chamber die casting and for this reason it has been included in this analysis.

As anticipated, these alloys have different compositions: they are indeed composed of the same elements but they are dosed in different percentages, so as to enhance specific characteristics such as resistance or fluidity. The following table shows the composition of the previously listed zinc alloys, defined by the European regulations EN 12844 European Standard for Zinc Alloy Castings and EN 1774 Zinc and zinc alloys – Alloys for foundry purposes – Ingot and liquid:

Zinc alloys chemical composition

The table highlights the different concentrations of the materials in the different zinc alloys, especially aluminum and copper concentrations: these two elements are indeed the ones that mainly influence the characteristics of the alloys.

Zinc alloys for hot chamber die casting

Alloy 2

Alloy 2 is characterized by high resistance and hardness: it is indeed the most resistant alloy among all zinc alloys. Aluminum percentage is equivalent to that of Alloy 3 and Alloy 5, while copper quantity is definitely higher: it can reach 3,3% and it is precisely this high copper percentage that provides an excellent resistance to the alloy. However, over time such a high amount can lead to the alteration of specific characteristics of the alloy: during metal aging it is indeed possible to observe some issues related to dimensions, such as a small dimensional variation. Furthermore, due to aging, the alloy can be subjected to performance decrease, which can reach levels similar to those of aluminum alloys: as a matter of fact, the main disadvantage when employing Alloy 2 is related to performance reduction, particularly a reduction of ductility over time. Despite this performance loss caused by aging, Alloy 2 is an excellent material for die casting thanks to its exceptional castability and creep performance, as well as its ability to maintain high resistance and hardness standards also during long-term aging.

Alloy 3

Alloy 3 is the most popular zinc alloy in North America: it is indeed the mostly used alloy because of its excellent castability and dimensional stability over time. Alloy 3 has a superior dimensional stability compared to the other alloys, however this high stability degree is only significant when very narrow tolerances are required. As far as resistance is concerned, Alloy 3 is characterized by a low percentage of copper that implies a lower resistance compared to the other zinc alloys but, at the same time, it reduces the likelihood of alterations due to material aging, thus avoiding dimensional shrinkage and maintaining a constant performance over time. This zinc alloy is also perfect for the production of components that need surface treatments, such as plating, painting and chroming.

Alloy 5

Alloy 5 is the most commonly used zinc alloy in Europe. This alloy has outstanding castability properties and, compared to Alloy 3, it contains a slightly higher copper percentage that gives the alloy a superior resistance and hardness, as well as a better creep performance. This higher copper quantity is though responsible, as previously seen, for an inferior ductility that can affect the processability of the alloy during secondary operations such as bending, riveting, pressing or crimping. Similarly to Alloy 3, Alloy 5 is an excellent choice for products that require surface finish treatments.

ZA 8

ZA8, as suggested by the classification ZA and not Alloy, is characterized by a chemical composition that has a high aluminum amount, considerably higher compared to the other zinc alloys. This high aluminum concentration provides the alloy with a superior resistance, hardness and creep performance in relation to the other alloys, except for Alloy 2 that has very similar features. ZA 8, like the other alloys, is appropriate for surface finish processes such as chroming and painting.

Main characteristics of zinc alloys

Through the analysis of the chemical composition of zinc alloys it is therefore possible to define which alloy is the most appropriate for one’s own sector, not only on the basis of mechanical and physical properties of zinc alloys, but also with regard to the features of the product that has to be realized.

The choice of the best zinc alloy for hot chamber die casting indeed starts from an examination of the characteristics of the component:

• Which are its most significant features?
• Is it an aesthetical or a functional product?
• Will it undergo surface treatments?
• Does it require a higher resistance or a greater dimensional stability?

Answer similar questions and therefore conduct a careful analysis of the requirements of the product is indeed the first step for the choice of the raw material.

Once the main characteristics of the product have been identified, it is possible to analyze the properties of the different zinc alloys.

As their previous descriptions report, the most significant characteristics of zinc alloys are castability, resistance, hardness, dimensional stability, creep performance and suitability for surface treatments. Now we will see these properties in detail.

Castability

The four zinc alloys mainly used for hot chamber die casting have all an excellent castability: it is exactly this feature that makes them specifically suitable for hot chamber die casting. High castability levels allow the die caster to produce components characterized by very thin walls, which are lighter compared to components produced with other metals. This ability to obtain minimum thickness leads also to a remarkable saving in terms of costs.

Resistance and hardness

Zinc alloys with the highest resistance and hardness are Alloy 2 and ZA8. Alloy 2 indeed contains a high copper percentage that gives it a particular resistance, while ZA8, despite having a copper amount similar to that of Alloy 5, is more resistant and hard thanks to the extremely high aluminum percentage (8,0-8,8%). These two alloys are therefore perfect for the production of components that need a great resistance and hardness but do not require specific dimensional parameters.

Dimensional stability

On the contrary, products that need a high dimensional stability over time should be produced using Alloy 3 or Alloy 5. These two alloys have indeed the right copper percentage to ensure a good resistance, while at the same time assuring dimensional stability over time. They are an excellent choice for the production of components with very complex shapes that require minimum dimensional shrinkage in order not to compromise the functionality of the product as time goes by. Thanks to this balance between resistance and dimensional stability Alloy 3 and Alloy 5 are the most widely used zinc alloys respectively in North America and Europe.

Creep performance

As far as creep performance is concerned, the most efficient alloys are Alloy 2 and ZA8. However, also Alloy 5 has a good creep performance, superior to that of Alloy 3, consequently it is more suitable to be used at high temperatures under a continuous stress.

Surface treatments

All zinc alloys listed in this post are appropriate for surface treatments: high fluidity of ZAMAK allows the die caster to apply various kinds of finishes, from chroming to powder coating. Zinc components can be worked in order to achieve almost every type of surface finish desired, thus obtaining aesthetically appealing products thanks to a shining chrome finish or a painting with intense and vivid colors, as well as smooth and silky surfaces thanks to satin finishing.

How to choose the most appropriate zinc alloy

Ultimately, to choose the most appropriate zinc alloy for one’s own product it is essential to focus on two main concepts: which are the characteristics that the final product should have and which are the properties of the zinc alloy that are fundamental to achieve these characteristics. If the component must be specifically resistant because it will be exposed to a high stress during its life cycle, then it will be more advantageous to choose Alloy 2 or ZA8. On the contrary, if the component needs a high dimensional stability level because it has very narrow tolerances, then it will be more convenient to choose Alloy 3 or Alloy 5.

Each product has specific and unique technical features that must be carefully examined in order to identify the most suitable zinc alloy, thus enhancing as much as possible the final outcome. The die cast supplier is consequently a valuable help when looking for the best zinc alloy to use because, thanks to the experience gained in different sectors and to the deep knowledge of the raw material, he or she can give precious advice for the achievement of the requested performance.

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The term automation defines the introduction in a manufacturing company of technical tools and processes aimed at reducing or even eliminating human operations. Indeed, the most relevant benefit of automation is the reduction of workload for the operators, which consequently leads to additional advantages such as reduced lead time, costs reduction and achievement of quality standards requested by clients. Automation can therefore contribute to production process improvement, enhancing accuracy, precision, productivity, robustness and consistency of outputs.

CASE STUDY

In Bruschi we are always seeking for innovative solutions that can help improving the productive process. In order to fulfill this aim, the production department has developed a project for reducing operators’ workload with the introduction of automation. This project concerned two specific components produced for a client of the sector of small appliances and has obtained excellent results in terms of reduction of manual activities of operators and increased productivity.
In order to define the two components to optimize among those available, engineers have conducted an analysis with the support of the Pareto chart, which has led to the following results:

• 20% output produced by 0,05% of components
• 60% output produced by 17% of components
• 20% output produced by 82,95% of components

Results show that 0,05% of components generates 20% of the output produced by the company: these components are known as runner products. The presence of few components that generate such a substantial output allow the introduction in the production department of a specific automation without reducing productive flexibility of the company.

Definition of project’s phases

After having selected the components, the different stages of the project can be defined. The iterative improvement process is indeed divided in four phases, with reference to PDCA cycle or Deming cycle:

• Phase 1 – PLAN
Definition of the problem, identification of the causes and hypothesis of corrective actions to reach expected objectives.

• Phase 2 – DO
Implementing corrective actions defined in phase 1.

• Phase 3 – CHECK
Collecting and checking data. Comparison between expected results and observed results.

• Phase 4 – ACT
Implementing corrective actions emerged from data analysis of phase 3.

The four phases of PDCA cycle have been planned using the following Gantt chart:

Phase 1 – PLAN

The first phase starts with the definition of the problem: a condition of misalignment between production capacity and client’s request, with hypothesis of producing both the components on the same die casting machine due to plant saturation. Therefore, the problem can not be solved producing the two components on two different die casting machines: it is in fact necessary to improve the production process of the components.
The identification of the root cause involves the study and the definition of the average duration of single activities, manual and automatic ones:

• Die casting – automated operation managed by the machine
• Pick up and lay down of the piece – automated operation managed by anthropomorphic robot
• Degating and reprocessing – manual operation managed by the operator
• Auxiliary activities – manual operation managed by the operator

Once average duration of every single activity has been calculated, improvement focuses on activities that can generate more benefits, so the ones that take up the most of the time of the operator. Manual activities that have been selected are reprocessing, raw-scrap division and die casting machine fueling: these activities take up 97% of the operator’s time.

The second step concerns the classification of operations on the basis of the added value they generate for the customer:

• VA = 0 % – Necessary Value Added activities: known, therefore paid by the client
• NVA = 3 % – Unnecessary Non-Value Added activities: unknown, therefore not paid by the client
• NNVA = 97% – Necessary Non-Value Added activities: unknown, therefore not paid by the client

First of all it is essential to work on NVA activities, in order to understand how to eliminate them. Secondly, NNVA must be analyzed and improved. Normally, VA activities can be improved but with little margin.

Phase 2 – DO

Phase 2 involves a cost-benefit analysis in order to identify the best solution between externalization and self-improvement through automation. Both the alternatives have been implemented:
• externalization of manual activities equal to 50%
• reduction of manual activities equal to 45%, through introduction of automation that operates automatic division of the pieces from the sprue runners and automatic recasting of the sprue runners

Phase 3 – CHECK

The third phase of the project involved collecting and checking data, with comparison between expected results and obtained results. Observation period after improvement actions have been implemented was of 240 working hours. Three numerical KPI (Key Performance Indicators) have been considered in order to evaluate the efficacy of improvement action:

1. OEE (Overall Equipment Effectiveness)
2. Average duration of manual activities
3. Tons of zamak recasted in the machine spot

The comparison of these indicators before and after improvement actions has highlighted +33% OEE and -95% manual activities, with a complete recasting of scrap material.

Phase 4 – ACT

Phase 4 has not concerned any action because after KPI analysis no anomalies were observed.

ACHIEVED BENEFITS

The project has led to several benefits for the production department, both direct and indirect ones.

Direct benefits:
• +33% OEE
• -95% manual activities
• Complete scrap recasting in the machine spot

Indirect benefits:
• Increase of client’s satisfaction. Met and reduced lead time thanks to productive capacity increase, improvement of superficial quality of the component and stabilization of degating and reworking processes
• Energy saving associated with immediate casting of raw material
• Reduction of waste due to handling associated with elimination of scrap transfer

This case study demonstrates the importance of automation in a productive system that is efficient and technologically advanced: through the introduction of automated systems it was indeed possible to meet qualitative and quantitative standards demanded by the client, meeting the requested deadline at the same time.

If you are interested in production process improvement, here are additional posts:
• Production process improvement in the die casting industry
• Casting process optimization: design of hot chamber injection system

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As the Journal of Industrial Engineering International reports, customers are more and more calling for environment-friendly products and this demand puts pressure on the whole supply chain, because it involves manufacturers, suppliers, retailers and customers. The latter are asking for a greener supply chain that promotes environmental protection and, at the same time, are also developing a well-defined purchasing behavior, which avoids unsustainable products and services. Businesses are therefore studying new methods in order to reach green supply chain management (GSCM), the integration of environmental issues and supply chain that results in reducing manufacturers’ impact on environment while enhancing an organization’s performance.

White goods recycling system

As far as white goods are concerned, emphasis is placed on their recycling cycle: manufacturers must therefore focus on materials. According to AHAM, the Association of Home Appliance Manufacturers, household appliances are increasingly being recycled: they are overtaken only by automotive industry as a source of recycled materials. The growing interest towards recycling has allowed to achieve significant results in the household appliances industry, also thanks to the United States Environmental Protection Agency, specifically with the Responsible Appliance Disposal (RAD) program, which in 2017 has recycled almost 70 million pounds of ferrous metals, 4 million pounds of nonferrous metals, 17 pounds of plastic and 3 million pounds of glass. As data highlight, consumers are increasingly aware of the importance of recycling and are more and more adopting a responsible and sustainable purchasing behavior: white goods industry is therefore continuously renovating and appliances’ manufacturers must face new challenges that environmental consciousness generates, developing products with recyclable materials through sustainable processes.

Metals recycling

White goods are characterized by a long life cycle, normally 10 to 18 years, and when they are no more usable they provide a consistent amount of recycled materials, specifically metals. As stated by The Global Metal Waste and Recycling Market report, the most recycled metals are iron, steel, aluminum, copper, lead and zinc; in addition to that, the report indicates the leading recycling industries, which are building, automotive, shipbuilding and consumer appliances. Metals are among the main materials that undergo a recycling process: they are perfectly suitable for recycling, indeed metals are valuable, can be easily transported thanks to their density and, furthermore, they present properties that allow them to be recycled repeatedly. In the U.S. metal recyclers manage thereabouts 120 million tons of recycled metal every year, with the metal recycling industry having registered nearly $27 billion in 2018.

Zinc recyclability

White goods are complex machines composed of several elements and different materials, among which zinc represents an intelligent and recyclable choice. As a matter of fact, zinc has exceptional metallurgical and chemical properties that remain unchanged also after recycling process, making zinc a suitable material for a wide range of modern products, such as white goods and small appliances.

To calculate zinc recycling rates experts rely on two main methods: the End of Life (EoL) recycling rate and the Recycled Content. Usually EoL is preferred because it measures the quantity of available zinc recovered at the end of product life and recycled, whereas the Recycled Content approach considers the amount of recycled material in a given product. Recent analyses report that around 45% of zinc at the end of life is estimated to be recovered and recycled; in developed regions, such as Europe and North America, this percentage reaches 50%.

Typical Recycling Rate Indices

What is more, zinc not only is itself recyclable, but also contains numerous substances that are recyclable: this quality certifies zinc as Cradle-to-Cradle (C2C), a concept inspired by nature that promotes circular economy. According to this approach a product is designed already considering future reuse and, at the end of its life, it is seen as a new source instead of waste: materials and elements that compose the product are thus recovered and again inserted into the processing cycle.

Zinc benefits in white goods manufacturing

Taking into consideration customers’ request for quality products manufactured with sustainable practices, zinc constitutes an ideal material for white goods components. Indeed, zinc presents high recycling rates and excellent aesthetical quality, combining two of the most demanded characteristics by end-users. Highlighting zinc properties can therefore be an efficient promoting strategy, thus meeting customers’ expectations, providing environmental-friendly solutions and improving selling rates.

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AUTOMOTIVE DIE CASTING Exterior PARTS: ZINC 

Related to automotive die casting exterior parts important to say that zinc die casting has many different benefits such as:

– Cost saving: zinc die casting has a process that offers a wide range of shapes and components if compared to other manufacturing techniques
– Precision: zinc die casting technique allows to produce complex shapes with closer tolerances. Moreover is possible to produce heat and wear resistance part that are dimensionally stable but maintaining close tolerances
– Excellent finish: is possible to manufacture parts with smooth and textured surfaces easily plated with a minimal surface preparation
– Longer tool life: is possible to produce millions of identical parts before a new tooling is required

Now we will deeply analyze why using zinc can be considered a plus in automotive die casting parts. In details zinc alloys can be used for interior parts or exterior parts. A previous post explains how zinc die casting can improve the perception of car interior value (click here for the post) while, in this article, the subject will be more focused on external parts of a car.

Why producing exterior car parts with high pressure zinc die casting

As said is possible to use high pressure zinc die casting both for car exterior parts and for interior: in this article we will analyze car exterior parts. In fact hereunder are listed the most common exterior car parts, or components of that, which can be produced using high pressure zinc die casting.

• Sun roofs
• Door opening system
• Pumps housing
• Symbols+signs
• Tank filling cover
• Rear lamps
• Antenna

The reason to choose zinc alloy is simple because this material has a better combination of toughness, bearing, rigidity, strength, performance and economical castability if compared to other materials.

High pressure zinc die casting is useful to produce components aligned to customers’ requirements.

For these reasons is possible to obtain innovative shapes and unconventional finishing, eliminating extra machining operations and cutting unnecessary costs. In order to produce parts or products aligned to functional or aesthetical aspects, high pressure zinc die casting can be used as an advantage.

To get an overview about zinc benefits in automotive read the following case studies about door opening system and sun roofs.

CASE STUDY n° 1 – The unexpected zinc weight role: door opening system
For a leading player in door handle systems, specialized in automotive, Bruschi produces special counterweight for locking parts. In this case, zinc alloys added value thanks to its specific weight: surprisingly, in terms of automotive, in this case weight is an advantage. Zinc die casting technology allows to strictly control the weight of the product: in this way, weight becomes a functional factor of the systems.

CASE STUDY n° 2 – No secondary operation for the required surface roughness: sun roofs
For an important car manufacturer tier 1 Bruschi produces brackets with guides for car sunroof. These brackets with guides are very precise running guides with complex shapes. Thanks to zinc die casting technology these components do not need secondary operations for the required shapes and even for the grade of surface roughness.

Develop automotive die casting parts in co-design way

To develop products and solutions like that is necessary a strict collaboration between the client and the die casting supplier. This process is fundamental to realize a product that has technical characteristics requested for its functionality and its aim and is at the same time in compliance to the process of die casting, finding the most suitable solution for the car.

This co-design activity is composed of three different phases: Process design, Cost analysis and Product design. In each step the collaboration between die caster and client it should be involved. Following a brief explanation of that.

Process design
In process design phase is important to define the different steps in the production cycle related to the die casting process, taking into consideration multiples variables among different departments.

Cost analysis
The second step about cost analysis is necessary to analyze how much the entire process will cost: a cooperation between parts can be the way to find the economic efficiency of the product, both for the die caster and for the customer.

Product design
The last phase is about product design where the analysis of the shape, geometry and function of the product are related to mechanical characteristics, resistance to static and fatigue stress, aesthetic quality and functional features. Based on the customer’s needs this is the step where an experienced and skilled die caster can make the difference.

To get a complete overview about the importance of product design in die casting engineering: Click here

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The post Advantages of Zinc for automotive die casting exterior parts appeared first on Bruschi.

Bruschi, as a die casting supplier of some of the most important manufacturers in this field, suggests to use zinc to develop components for sunroofs to take advantages of design, materials, processes and systems.

A research about sunroof implementation says that its use will grow exponentially in the next few years.

According to the forecast the global automotive sunroof market will grow of 11.22% during the period 2017-2021. This report is based on in-depth market analysis and covers the landscape and its potential growth for the coming years. In the report is also included a discussion about key vendors of this field.

Click here for the research

Why is zinc used for car sunroof?

It is more advisable because it guarantees a better precision of shapes and less secondary operations compared to other materials and, regarding the green way, it is recyclable.

For example, it assures less secondary operations than those needed for aluminum. In fact aluminum has an higher melting point, for this reason many secondary operation are requested to reach the same precision compared to casted zinc. In addition, it allows to reach a better surface quality, in terms of sliding of other components, thanks to its smooth surfaces. It is hard to reach the same roughness rate with Aluminum die cast components, and that is why very often secondary operations are necessary to reach the same target of smoothness. This implies higher production costs.

When compared with plastic, metal alloys castings are stiffer. Only special kind of plastic (such as glass fiber reinforced polymers) can be equally stiff, but in this case the process will be more expensive: the use of zinc will allow a saving in economic terms.

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The post Zinc benefits for Car Sunroof Manufacturer appeared first on Bruschi.