The component in question is linked to the safety of the vehicle’s driver and passengers. Due to its very nature, it requires a maximum tolerance of a few thousandths compared to the required weight of 6 grams. Such a tight tolerance level is challenging to be respected 100% in producing die-cast parts.

Bruschi’s R&D team and technical office took the lead in developing a pioneering project in the sector. Leveraging software development and cutting-edge technologies, they overcame the common limitations of die-casting production and met the customer’s demand.

Therefore, the mass production of zinc pieces smaller than a €1 coin was guaranteed, respecting the tolerance specifications provided by the customer.

Bruschi designed and implemented a fully automated production process to ensure precision and quality. This process involves the use of robots equipped with precision grippers capable of extracting the die-cast components from the molds. A camera placed on the machine allows the robot to independently verify the presence of all the pieces inside the mold, dismantle them, and place them on a precision scale for quality assurance.

Any pieces that do not meet weight standards activate a reject system.

This is an example of how technological progress and engineering skills make it possible to satisfy the market’s needs, overcoming production limits that only a constantly evolving company can overcome.

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In recent times, automotive manufacturers are more focused on manufacturing lightweight automobiles without affecting durability of the vehicles. Therefore, die casting is one of the most valuable techniques adopted by the manufacturers for creating automotive parts. The number of die cast parts used for automobiles continues to rise daily. Some of the main reasons for the increase in demand of die casting by the manufactures are:

Increased precision, efficiency and cost effectiveness

Die casting is a technology that helps in increasing precision, efficiency and cost effectiveness of the automobiles / vehicles that are getting manufactured by using die casted products or components. Die casting is also one of main reason behind numerous automotive advancements that are witnessed by all of us. With the ability to mold materials such as zinc, aluminum and magnesium alloys, die casting unlocks various other opportunities that helps in elevating vehicle performance boosting in an overall growth of automotive industry.

Helps in fuel efficiency

The inclusion of die cast components in the automobiles, mainly in engines, also helps in fuel efficiency as the overall weight of the vehicle reduces when die casted components are used which also results in lower emissions resulting in reduction of pollution and better vehicle performance that helps in production of more units effectively and efficiently.

Increased automation and flexibility

The popularity of automotive die casting is increasing day by day all over the globe due to the high use of advanced technology in almost every industry. All the process becomes more effective and productive when the production process is automated. Moreover, die casting technique helps to create parts with complex shapes and sizes easily which ultimately makes the installation process smoother.

As discussed above, die casting helps to produce parts with complex shapes with high durability and improved aesthetic appearances. Following are some of the parts / systems from wide variety of applications of die casting for automobiles that includes:

• Engine parts
• Mounting brackets for electric motors and stepper motors
• Electronic covers for gearbox
• Sensor and airbag housings as active safety mechanisms
• Fuel intake parts
• Air conditioning systems
• Mounting brackets for stepper motors
• Retractor spools for seatbelts
• Transmission components
• Sensors
• Chassis components
• Durable power steering and braking systems

Advancements in die casting technology

As automotive manufacturers strive to stay at the top of innovation and adapt to new technologies, die casting technology has evolved to meet the growing demands of the industry which also helps the manufacturers to product the vehicles with the new technology that also helps in customer satisfaction. Some of the main advanced die casting techniques are playing a crucial role in achieving higher levels of precision and efficiency in automotive industry such as:

1. High pressure die casting

High pressure die casting involves injecting molten metal into a steel mold at high pressures that results in faster cycle times and enhanced part integrity of the vehicles. This type of die casting technology helps in the production of complex automotive components with minimal porosity, ensuring the highest quality and durability.

2. Vacuum die casting

In vacuum die casting, the process is carried out in a controlled environment with reduced air pressure. This method minimizes gas porosity in the final product that is being produced, further also improving the structural integrity of the automotive components. In recent times, manufacturers are increasingly adopting to vacuum die casting for manufacturing the critical parts, such as engine components and safety mechanisms.

Innovations in die casting materials

With the aim to create light weight yet robust automotive components, die casting industry has witnessed continuous material innovations. The incorporation of advanced alloys, such as zinc – aluminum alloys, has become prevalent. These alloys not only offer improved strength and durability to the vehicles but also provide a higher degree of corrosion resistance to them. The composition of the materials can also be customised as per the requirements which results in enhancing the overall performance of die – cast automotive parts.

This customization capability not only focuses on specific performance requirements but also opens various opportunities to include die casting materials for diverse applications in manufacturing other different components for automobiles. As a result, the evolution of die casting materials is not just about meeting the current industry needs but also about anticipating and adapting to future technologies and challenges in the automotive manufacturing industry.

Sustainable practices in die casting

In response to growing environmental concerns among the individuals and manufacturers, the automotive industry along with various other industries is also increasingly focusing on sustainable practices for most of the processes. Die casting foundries are also collaborating with many automotive manufacturers to implement eco – friendly measures in their production and all other operations. This includes the use of energy – efficient equipments, recycling of process water and the implementation of green manufacturing practices. This aligns with the automotive industry’s commitment to reducing its carbon footprint.
By aligning the die casting processes with sustainability goals, the automotive industry is moving towards a more environmentally responsible approach that will not only help the environment but will also help the companies in the long run.

Future opportunities

In the ever – evolving industry of die casting, several new and trending opportunities are emerging which is helping to push the industry towards enhanced capabilities and efficiency. Let us have a look at some of the possible future opportunities that lies there for die casting industry with respect to automotive industry.

New materials and alloys

Research into new materials and alloys is opening opportunities for enhanced die casting capabilities. Materials with improved strength and durability are being explored to meet the evolving needs of the automotive industry that will help in the manufacturing of different types of parts and components for automobiles that will be having more stability and resistance to make the final product much better from now.

Smart manufacturing and industry 4.0

The integration of smart technologies and industry 4.0 principles enables real – time monitoring and control of die casting processes. Predictive maintenance, data analytics, estimation of demand – supply and automation contribute to increased efficiency and reduced downtime which helps in the overall growth of the manufacturers as well as of the automotive industry.

3D printing and prototyping

The unification of 3D printing technologies in die casting processes allows for rapid prototyping and the creation of complex geometries that are required in day-to-day basis in automotive industry. This innovation accelerates the product development cycle of the parts and components that are manufactured and supports the customization of automotive components.

Collaborative research and development

Collaboration between die casting manufacturers, automotive companies, and research institutions fosters a scope for continuous improvement. Shared knowledge and expertise can lead to breakthroughs in die casting technology that can also help in analysing the challenges that are faced in the correct manner and take corrective actions and measure to tackle them.

Conclusion

In conclusion, the innovation and efficiency in automotive industry has led to the widespread adoption of die casting techniques, particularly in the manufacturing of light weight and durable components. Die casting not only enhances precision, efficiency, and cost – effectiveness but also contributes to fuel efficiency, automation and flexibility in the production processes that are done for the production of parts and components of automobiles. The diverse applications of die casting in creating complex parts for engines, safety mechanisms and various automotive systems throws light on its pivotal role in shaping the future of the automotive sector with the help of die casting in the process.

The evolution of die casting technology, including high – pressure die casting and vacuum die casting, showcases the industry’s commitment to achieving higher levels of precision during the process of production. Material innovations for die casting are also resulting in contributing to create robust and lightweight automotive components. Moreover, the industry’s increasing focus on sustainable practices focuses on environmental concerns emphasizing a responsible approach towards reducing the carbon footprint.

Looking forward, the automotive industry anticipates exciting opportunities in the near future, including the exploration of new materials and alloys, the integration of smart manufacturing and industry 4.0 principles, the adoption of 3D printing for prototyping and collaborative research and development initiatives. The points mentioned above not only promises improved and enhanced die casting capabilities but also signifies a collective effort towards continuous improvement.

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Products have been chosen on the basis of different principles: we privileged variety, selecting components that are produced for different sectors and complexity, in order to communicate our expertise and competence in satisfying the client’s requests.

Here the list of the videos:

• Die casting for household appliances: coffee machines
• Die casting for automotive: electronic steering wheel lock
• Die casting for automotive: sunroofs
• Die casting for building industry: windows and doors
• Die casting for household appliances: hinge for washing machines

Let’s give the floor to our experts.

Die casting for household appliances: coffee machines

In this video we show the production of a component for coffee machines and we describe the technical solutions implemented to obtain a perfect chrome finish.

This product is the bottom section of a coffee machine for the consumer market. It is an aesthetic component that comes into view and in contact with the end customer: for this reason there are specific technical and quality aspects to consider. During analysis stage, indeed, we have faced technical and process difficulties caused by the particular shape of the component, which could invalidate the requested standards thus reducing the quality of chrome finish.

It is exactly the particular geometry of the piece that does not allow the working of the internal surface and it is for this reason that, after careful analyses of the production process and considerations on the shape of the component, we decided to obtain a surface that was suitable for chroming process already after casting phase.

In order to reach this aim we have undertaken virtual and physical prototyping and simulation activities that have allowed the definition of optimal parameters for the production of the component. Thanks to simulation and prototyping we have identified two properties on which we have specifically focused our attention: roughness and surface quality. To achieve the expected result already during casting stage we tried to take the most out of production parameters. The lapping of the mold has been the chosen solution to obtain surface roughness already during casting phase; simulation and tests during production phase allowed us to modify the mold in order to obtain the requested surface quality and standards.

The adoption of these technical solutions and the modified parameters have therefore allowed us to obtain a product suitable for polishing and chroming treatments.

The polishing stage is carried out on still rough pieces, whose external surface is smoothed so that the subsequent chroming process has a good result. The next stage is indeed chroming phase. Chroming process is an aesthetic galvanic process that gives to the die cast a charming and protective aspect: the chrome surface, indeed, protects against corrosion. It is a process composed of various passages where the products are immersed in aligned tanks to receive sequentially processes of degreasing, copper plating, nickel plating and chromium plating. It is this final stage that gives, thanks to the extremely brilliant aspect, an important added value to the component, making it a distinctive element of coffee machines.

Die casting for automotive: electronic steering lock

In this video we present an automotive component whose mold has been designed in an unconventional way and on which it has been introduced an automatic threading system.

This component of the electronic steering lock has required an unconventional mold design because it is characterized by a complex shape. Indeed, the inner section of the product, which is designed to hold an electronic card and to contain sliding parts, has caused the main difficulties in mold design. Therefore, the structural complexity of the component, connected with the production process, has determined the necessity to obtain a considerable level of accuracy during mass production.

Considering that the product is designed to internally contain an electronic card and further functional elements, it is necessary the total lack of die casting defects (for example burrs) that could compromise the functionality of the product or of the elements inside the component. In order to achieve the requested precision and quality standards, mold has therefore been designed with an unconventional approach. The configuration with which it has been designed is indeed the opposite of the traditional one. The piece is picked up by its external part and not by the internal part as it usually happens: in this way we avoid both burrs and extractors in the internal part of the product.

After the optimization of mold design we also introduced during production cycle an automatic system for threading. This system, integrated into casting area, allows both the cutting of sprue runners and the simultaneous threading of two M8 holes. There are two important benefits that result from the implementation of this system: first of all we avoid manual operations (so the operator is free to deal with activities with greater added value) and, moreover, we obtain productive efficiency and continuity, with a resulting cost and time saving. Die casting technology, in particular die casting for electronic steering lock, thanks to our innovative approach and to the technical expertise of our engineers, constitutes a great choice for the production of automotive components because it ensures production accuracy also for the most complex products.

Die casting for automotive: sunroofs

In this video we present a component for automotive industry characterized by very close tolerances and complex geometries.

This part is a component for car sunroofs that has a complex shape and is characterized by very thin areas. Therefore it requires a high level of detail and accuracy. To meet the requests of the costumer we have adopted specific technical solutions that have assured the functionality of the piece and, at the same time, have allowed us to obtain a product free of every minimal deformation.

These solutions have been implemented in mold design phase and during the simulation of the filling flow, while the implementation of the injection channel, tilted sliders and ejectors has been managed in every detail to achieve complex shapes. For the simulation we have used Magmasoft software, which has allowed us to optimize filling flows in the entire die cast and in particular in the thinnest areas. The outcome has been a uniform and homogeneous filling. In addition, to increase even more the accuracy of the result, we have employed the vacuum technology, a tool designed and realized here in Bruschi to guarantee dimensional stability.

The technical solutions devised by the engineers have allowed us to achieve a product that has excellent technical features, compliant with our production process and that meets the complete satisfaction of the costumer. For the automotive industry, in this case for the production of sunroofs components, die casting technology allows the achievement of products with close tolerances and complex shapes that fully meet strict standards of the sector.

Die casting for building industry: windows and doors

In this video we show the production of the cover of the opening and closing system for windows and doors.

The component is part of the opening system for windows and doors: so it is characterized by functional and aesthetic properties. On the one hand, the functional properties are determined by the fact that the component contains in its inside other elements of the opening system. The aesthetic properties, on the other hand, derive from its nature of external element that comes in contact with the end costumer. For this reason the piece must have an optimal surface quality.

Therefore, to design and produce this component, we have considered various different aspects and we have found solutions able to ensure aesthetics and functionality. As regards aesthetics we focused on avoiding the formation of air entrapments in the die cast to obtain a surface suitable for powder painting. To obtain this kind of surface quality we used simulation software and the vacuum valve: these solutions permitted us to reduce painting scrap from 30% to about 0%. Concerning the functionality, instead, we have developed in collaboration with the costumer a re-design activity of the internal part of the component, aimed at reaching thin wall thickness that would maintain the properties of the product unchanged. Thin wall thickness, in windows and doors opening system, are important because the component has in its inside the fixing and the sliding system of opening mechanism and the reduction of thickness improves its functionality. The benefits provided by the reduction of thickness are considerable and concern less quantity of raw material and cycle time reduction. However, the production of the component does not confine itself to casting process. Indeed we have designed and realized an automation for the threading of 6 M5 holes. The threading phase is immediately after casting stage: the product passes through a vibrating device and after on a rotating table with three threading stations. The implementation of this automatic threading system has resulted in a considerable reduction of timing of the secondary processes.

Years of experience in die casting for windows and doors, technical skills and know how, have made it possible to produce a component characterized by specific aesthetic and functional properties and able to satisfy the costumer’s requests.

Die casting for household appliances: hinge for washing machines

In this video we show the production of the hinge for washing machine and the technical solutions adopted to guarantee the functionality of the product.

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Reference standard for Automotive Tier 1 and 2

A car consists of thousands of components. The automotive industry is therefore characterized by great complexity that occurs also in the different levels of the supply chain. In fact, the OEM (Original Equipement Manufacturer) is the last link in the production chain that goes from Tier 3, the nearest to raw materials, through Tier 2, suppliers of components, to Tier 1, suppliers of assembled parts.

IATF

To control this complexity and to ensure continuative quality to the components of the vehicles some regulations have been introduced, in order to standardize products and producers. The most important standard on the matter is IATF 16949:2016, developed by the International Automotive Task Force in 2016. This standard has replaced the previous ISO/TS 16949 and it stands alongside ISO 9001. IATF 16949:2016 has been created by the main OEM with the purpose of making it possible for Tier 1 and Tier 2 automotive suppliers to obtain reliable results for mass production, which are compliant with the high qualitative standards of the automotive industry.

IATF 16949:2016 is applied not only during production but also during the design phase and throughout the relationship with the customer. In fact the regulation contains, besides the parameters that have to be respected, also instructions on how to formulate offers, undertake feasibility studies and guarantee results from an economic, design and productive point of view, thus helping the customer to find appropriate solutions. In short, it makes it possible to work with every customer transversally, establishing rules that are universally valid in the automotive industry.

CSR

Even though IATF introduced uniformity among the requirements demanded to automotive suppliers, the complexity of the processes are still a typical trait of automotive industry. Just like Tier 1 works with different customers, on every level of the hierarchy, also Tier 2 and Tier 3 receive products from different suppliers and supply different customers. Every customer has its own particular requirements, called CSR, Customer Specific Requirements, that are, in short, a list of the specific needs of every customer. Hence, the skill of a Tier 2 or Tier 3, is to take CSR and IATF and to complement them with its own and with the customer’s productive process.

In order to meet CSR of different customers it is necessary to be compliant with their own standards and objectives. In the case of Tier 2 automotive supplier it means to have different control steps in every phase of the productive process, to monitor the development of the production from design to delivery and to verify norms and qualitative parameters compliance in every step.

Obviously, the compliance with the customer’s requirements must be incorporated to production in order to remain in a central position of the “time-scope-quality project triangle”:  depending on the characteristics of the customer the supplier must be able to move into the triangle without losing sight of what is priority.

Tier 2 automotive supplier: advantages of a SME

Not only industrial giants contribute to automotive production. Very different entities take part in the construction process of a car: they can be giant or big companies, such as OEM, or small and medium-sized enterprises.

It is exactly a SME, as Tier2 automotive supplier, that can prove to be more competitive than a bigger company. In fact a SME, thanks to its dimensions, is able to create a special relationship with its customer, which is expressed in terms of cooperation, flexibility, speed and trust.

Cooperation

Cooperation is not only about design and production but also about the intermediate phase of prototyping. The process that leads to the creation of a component is a development process that ends with the phase of ramp up, the phase in which volumes increase from pre-series to mass production. A SME that is structured to work with the automotive industry is able to cooperate with the customer in every phase of the productive process.

During the concept phase the supplier cooperates with the customer in devising the project for the component. In prototyping phase technical solutions are tested, evaluated and refined with short-run temporary tools.  With the pre-series stage the product is realized in short-run but with all the methods and  tools of mass production, in order to check the compliance of the production process of the component. Finally, in the last phase, the production one, the component is mass produced.

For further insights about simulation as a way to increase effectiveness and efficiency of production process in the automotive industry read the article Simulation for HPDC: surface aesthetical quality in automotive.

Flexibility, speed, trust 

A SME Tier 2 is able to guarantee to the customer great speed of response times. In the case of a corporate giant response times, due to the large size of the company can become longer. In the case of a SME, on the contrary, this does not happen. In fact, the moment the customer contacts the supplier, thanks to vertical and direct relationships, the SME Tier 2 is able to quickly react to requests.

Besides speed SME Tier 2 is also able to guarantee flexibility, both in terms of time and product. Even in the event of urgencies a SME is able to organize its production in order to meet the customer’s requests. It is also able to flexibly realize the different typologies of products, such as safety, functional or aesthetical products, meeting their own specific regulations.

The relationship of trust and transparency between customer and supplier is a further added value given by a SME. Business partners, in a SME, are people that know each other with whom it is possible to talk promptly about any possible difficulties in order to cooperate and to find solutions. The larger a company  gets, the easier it is for this relationship to get lost, together with the already mentioned speed, flexibility and trust.

A Tier 2 automotive supplier that is also a SME is thus an entity able to combine compliance to the strict productive and qualitative regulations of the automotive industry with flexibility, speed and trust. Moreover, as said, it is able to create a personal relationship with customers and to directly cooperate with them in order to define the most appropriate, safe and favorable solutions.

If you wish to deepen the topic advantages of zinc alloys for the automotive industry you can read the article The importance of zinc die casting in automotive industry.

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You can find a full list of discussed topics in our first post on the subject, by clicking here.

CASE STUDIES AUTOMOTIVE: Surface aesthetical quality

The subjects of this case study are the thin plates in car vents that direct and control air flow in the car’s passenger compartment.

The vents for air flow control are usually made of plastic, but the object of our case-study is the central plate, used by the driver to direct the other air ducts and therefore made in alloy.

This product poses challenges especially for the surface aesthetical quality, because of its exposed position in plain sight inside the passenger compartment, the high-end car on which the vent will be installed and possibly the criticalities of surface treatment after die casting.

OBJECTIVE AND PHASES OF THE SIMULATION

The simulation analysis will thus focus on engineering an optimal flow through the feeders to avoid defects such as flow marks and blisters in the product.

In the first phase of the process we studied the effect of various runner configurations, one by one, to identify the runner with the best characteristics. Then we improved the shape of the runners, especially at the entry of the die.

The objectives sought in the various phases of the simulations were:

• Filling consistency of the die according to a main flow direction
• Decrease of the probability of cavitation to increase the speed of flow
• Reducing the filling time and keeping the alloy at a high temperature during this phase
• Absence of air bubbles in the product

RESULTS

In the study of product surface quality, the main parameter to consider is temperature. The temperature must be maintained the highest and the most consistent possible throughout the duration of die filling up to the end of filling process, especially in parts of the product that will be in full sight.

The images portray the analysis results at filling cycle end: the temperature is sufficiently high and homogeneous, with even better characteristics in the top surface, which requires a higher level of quality since it will be visible in the compartment of the car it will be installed in.

From the velocity field analysis it is possible to observe the feed direction and the speed modulus at the die entry point: a particularly critical point because it is often subject to cavitation phenomena, causing die wear.

By looking at the picture, we can notice filling consistency and that the last volumes to be filled are close to the overflows, allowing the exit of the first alloy arrived in the die, because the temperature will be lower.

The velocity field, depending not only on the runner geometry but also on boundary conditions at die entry level, has been obtained by using process parameters common for die casting this kind of product. The speed pattern is sufficiently low even in the vicinity of the gates. This has a positive effect on manufacturing because it will allow to apply higher filling parameters without the risk of premature wear of the die.

The next image shows that the impact of the runners is well balanced: the two runners, identified by red and blue colorings, fill the die in a consistent manner. Proper functioning of the small runner on the left is confirmed: the presence of the orange color, as small as it is, is necessary to avoid flow marks.

The influence of runners (orange liquid) should be reduced but not zero: it’s presence may be necessary in order to avoid flow- marks in the entry zone.

And finally, the field that shows trapped air indicates a favorable situation: the air contained in the casting is not an issue because it distributed evenly across the volume and concentrated only at the sprues, granting the achievement of requested surface aesthetical quality.

All of these analysis confirm that the design and the filling system are optimized to obtain the best esthetic quality, granting a smooth surface that can undergo the required coating and contribute to the perceived value of car interior.

In conclusion, the simulation study allowed us to assure the best surface aesthetical quality for air flow vents, by analyzing four main factors: main flow direction, speed of flow, filling time and temperature, absence of air trappings. Thanks to the analysis of these factors, it was possible to optimize the casting process by redesigning the shape of the runners and thus to fulfill the requested levels of esthetic quality.

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With casting process there is often no need of further machining after casting: not only its accuracy is up to 99.8%, but casted products also can be used raw, since they have a pleasant finish. Zinc die casting usage is almost 28% in automotive industry, followed by building and hardware sectors.

Zinc has become one of the most important metals in automotive parts industry, especially for products like door lock housing, pawls, retractor gears and pulleys in seat belt system, but also for the camshaft and sensor components. By using this metal and its alloys, it is possible to reach a strength, ductility and malleability that will not be possible with other materials.

Moreover, zinc can be the right choice to obtain high quality aesthetic components, with  strict tolerances impossible to achieve with other materials, and to obtain embossing and grooves for mechanical or gear components.

Automotive zinc die casting components

As said before, automotive industry is the most common application of die casting: by using zinc and its alloys is possible to produce components capable of reaching high aesthetic quality , with strict and narrow tolerances for shapes morphology. Zinc alloy is also used for plating purposes because of its many benefits, such as enhancing the already impressive anti-corrosion zinc properties.

Hereunder you can find a selection of examples of what is possible to produce with zinc plating:

• Interior aesthetic parts
• Sunroofs parts
• Mechanical parts
• Engine and other under-the-hood components
• Power steering systems
• Brake parts and systems
• Air-conditioning components and systems
• Chassis hardware
• Parts in seat belt system
• Climate control components
• Fuel systems

In the next paragraph, we will proceed with a list of zinc alloys advantages.

Zinc alloys advantages

Zinc alloys in die casting allows to develop products and to simplify production, providing a durable end-product. Zinc strength, ductility and stability allows specialists to obtain a better and more resistant product. It is this high ductility that makes zinc ideal for die casting process, in which it is necessary to sustain pressure and expansion without fracturing. Other zinc alloys advantages are used in die casting, such as:

• Electrical and thermal conductivity
• Raw material low cost
• Strong stability, which grants a long-lasting end product with high quality finishing properties
• Thin walls: they contribute to corrosion resistance for end products, increasing their durability in harsh environment
• Economical for small parts
• Low melting point, which means it requires less energy for production
• Dies have a longer tool life
• Complex geometries and quality finishing: by using zinc it is possible to cast intricate, thin walled and technically demanding parts with high precision
• Top quality coating and chrome plating: zinc die casting components are fit for electroplating

Zinc vs other materials

Each alloy has its own characteristics in terms of physical and mechanical properties: these factors are fundamental to determine longevity, strength and functionality of products. Product complexity, its wall thicknesses and the required precision will influence how castable it is: these elements should be considered main points to better organize a die casting production.

There are different methods of die casting, depending on design application and metal choice: hot chamber or cold chamber are just two of them. Hot chamber die casting is ideal for metal with low melting temperatures, for example zinc or magnesium, while cold chamber processes are used for alloys such as aluminum, which have higher melting temperatures.

Zinc alloys compete with other materials in die casting industry: aluminum, cast iron, machined brass, machined steel and magnesium, together with zinc, are the most commonly used metal in die casting products. Choosing alloys is a tough operation: the die caster has to analyze application, material density, tensile strength, yield strength, melting temperature and elasticity to obtain a better outcome with all its functional and aesthetical requirements.

1. Zinc alloys vs Aluminum

One of the main difference between aluminum and zinc alloys is zinc low melting temperature and its need for lower pressure during die casting. For these reasons zinc alloys are the most castable ones. Having a low melting temperature allows zinc die casting tools to last longer, and since dies are expensive, using them for a longer time is a cost-effective approach to high volume of production.

Moreover, zinc can be cast with HPDC, which is less expensive than cold chamber process; by using HPDC it is possible to increase production speed. Aluminum alloys, on the other hand, are normally casted with cold chamber procedure, which is less productive than hot chamber process used for zinc.

In addition, zinc is more suitable for very detailed castings and very little machining or finishing work is needed after ejection of the component from die: low pressure and low melting point reduce thermal shock during casting, giving a smoother surface to the component. Moreover, the superior zinc formability and machinability gives costs advantages in finishing and assembly operations.

There is another downside to aluminum die casting: it tends to produce sparks after impacting against iron or steel. This forbids its use in risky environment where explosive atmospheres can develop. Instead, zinc is a non-sparking material and thus it is free from this risk and it is suitable even for those environments.

In general, zinc has a better precision, smaller draft angles, smaller and longer cored holes, much longer tools life, thinner wall sections possible, superior tensile strength, better machinability, better formability, lower casting costs, superior pressure tightness, more finishing options and it is a non-sparking material when compared to aluminum.

2. Zinc alloys vs cast iron

Zinc, in comparison to cast iron, has lower casting costs, more precision and superior thermal and electrical conductivity. However, it is difficult to compare cast iron with zinc alloys because there are a large range of materials for iron casting, each with different properties, so that is impossible to strictly define them.

3. Zinc alloys vs machined brass

Zinc alloys have lower process costs, lower material costs, less process scrap and equivalent or superior tolerances achievable than machined brass. As before, the term brass regards a wide range of cast materials, with many different mechanical properties and is impossible to define each of them.

4. Zinc alloys vs machined steel

Compared to machined steel, zinc has lower process costs, a superior corrosion resistance and equivalent or superior tolerances achievable.

5. Zinc alloy vs magnesium die castings

One of the main differences between magnesium and zinc alloys is that zinc alloys need lower pressure and temperature for casting. Unlike magnesium, which requires a special treatment for corrosion resistance and finishing, zinc alloys have excellent corrosion resistance and a better surface right after being ejected from the die.

Magnesium has a really low density and, just like zinc, magnesium alloys can be die casted using HPDC: for this reason, they have faster cycle times than aluminum. However, zinc properties are superior to those of magnesium in every aspect.

Zinc, when compared to magnesium, has lower processing costs, lower draft angles, better precision, superior stiffness, superior tensile strength, better corrosion resistance, superior formability, longer tool life, more finishing options and it is a non-sparking material.

CASE STUDIES

The use of zinc in die casting processes allows a series of finishes that would be unachievable with other alloys, leading to products with both high technical coefficient and important aesthetic value.

Bruschi has 70 years of experience with clients of several industries, including automotive, lightning engineering, household electrical appliance, doors and windows locks. Having a wide know-how that extends from one field to another allows the designer to provide his clients with alternative solutions inspired from other industries and always ensuring top quality in material, processes, manufacturing and durability.

In addition, an analysis phase preceding mold design leads to proposals aimed at reducing scraps,  minimizing production costs.

Hereunder a selection of case studies focused on automotive sector.

CASE STUDY n° 1 – New finishing to avoid blistering

An important automotive player asked Bruschi to produce a component in order to find a solution for its scrap rate: it was already being produced by another supplier, but it had a scrap rate of over 25% due to blistering, appearing after treatment of galvanizing coating.

Bruschi worked focusing its efforts, involving its supplier network, to avoid blistering. The solution was to  change the finish: shifting from galvanizing coating to passivation. This meant a great reduction of scrap rate caused by blistering, that decreased from 25% to only a few parts per million.

CASE STUDY n° 2 – New finishing to improve SST resistance

An important automotive player asked Bruschi a solution to improve the salt spray test resistance of a  product. The component needed a higher SST resistance for a new project, in which the component would become part of luxury cars.

The SST resistance is given by a particular kind of finishing, called Fe/Zn: for subcompact cars the guaranteed resistance is 120 hours. However, this treatment was not suitable for luxury cars. The new goal was to push the resistance up to 1000 hours. Thanks to Bruschi expertise and network, our client reached its goal by applying a special galvanic treatment, which improved SST resistance to over 1000 hours.

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In their study titled “Automotive Parts Zinc Die Casting Market – Size, Outlook, Trends and Forecasts (2018 – 2024)”, latest data are presented on the revenue numbers, product details, and annual  generation of revenue of some major firms. In addition to this, the report also covers competitive analysis in marketing and strategic management, monitoring of the external and internal factors which affect the market dynamics and Regional and Global Variety.

We will now see in details the core topics and conclusions of the report.

Zinc die casting in automotive

Zinc die casting is commonly used in automotive industry because of its high degree accuracy and reliability even with mass scale of production. Zinc characteristics of high manufacturability, precision, strength and wear resistance makes it an ideal material for many different uses, both for car interiors and exteriors.

Zinc die casting also offers many advantages in terms of cost saving and design freedom, thanks to its process that requires lower energy costs for smelting and longer tool life than aluminium, its close tolerances precision, its excellent finishes for smooth and textured surfaces. This is why, while being used in smaller quantities than aluminium, zinc is still fundamental for the construction of some components, such as door locks, inertia disks, retractor gears, pigeon gears, sensor components and others.

Growth of Zinc Die Casting Market in Automotive

According to Envision Inteligence report, zinc die casting in automotive parts market valued at $2.55 billion in 2018 and is estimated to reach a value of $2.92 billion in 2024 at CAGR (Compound Annual Growth Rate) of 2.75%.

This result is given by the intertwining of complex variables, that determine the growth of the market. Some factors, such as the increased costs of raw material, could lower the consumption of zinc in automotive market. However, the global growth of automotive market and zinc benefits in terms of functionality and aesthetic features of zinc, widely counterbalance the decrease in consumption in favor of zinc alloy use. 

All of these elements combine in a positive payoff, represented by a positive growth.

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About Envision Inteligence

Envision Inteligence is an agency working within the areas of market analysis, enterprise intelligence and consulting. They are experts in analysis and consulting for numerous enterprise domains to cater to the wants of each particular person and company shoppers, enhancement, company financing and resolution making based mostly on market analysis, helping in growing acceptable technique and offering consultancy based mostly on in-depth analysis.

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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.

Zinc pressure die casting allows a better mix of strength, toughness, rigidity, bearing, performance and economical castability if compared to other materials. Its properties are better than other materials such as aluminum, magnesium, bronze, plastic and other cast irons in case of high aesthetic value requirement.

ZINC PRESSURE DIE CASTING IN CAR INTERIOR PARTS

Using zinc pressure die casting in car interior parts can be considered an advantage in order to produce products aligned to aesthetical aspects, eliminating extra machining operations and cutting costs.

It is possible to use this technology in both interior and exterior parts, but in this article we will analyze car interior parts. A car is composed of thousands of parts and zinc may also be joined for ornamental purposes in interior details.

Add aesthetic value to products or components in car interior allows to reach important goals to get the attention of end users in terms of perception of the car.

So first of all let’s try to define perception in a few words.

Perception is an approximation of reality and it can be influence by several variables. It can shape thanks to different factors but, to be consciously processed, attention is needed. In order to reach the goal of improving product perception, by considering attention as the act or state of focusing to something, the most important thing could be an eye catching design solution.

This solution should be different and innovative, also placed in a common or familiar area as car interior. To develop something like that the solution could be produced in zinc pressure die casting.

The perceptions has dramatic effect in buyer’s journey and this is really important also in car. By using this technology in car interior parts could be the competitive advantage to reach buyers attention by working on their perception.

Following short briefs of that.

• Increase car economic perceived value
• Improve car segment perception
• Influence car driving experience

Increase car economic perceived value

Metals and innovative design with high aesthetic value in car interiors can boost perceived value of the whole car. First of all we start focusing on metals. Using metal instead of plastic, considering all the safety implications, can help to improve the sense of touch feeling and help to define the first impact decision in a potential customer. This perceived high quality meet consumer expectations and it is necessary for product differentiation. Once choose metal instead of plastics injection molding technology, the second step is to choose which metal. In the world of metals, to reach innovative design, zinc pressure die casting can makes the difference. In fact, pressure die casting can be used to produce more complex products or components in mass production terms. In fact zinc allows, compared to other alloys such as aluminum, to create smaller draft angles, thinner wall sections and smaller cored holes. Due to its technical characteristics allows the chance of having high quality aesthetic finishing thanks to its smooth surfaces and an higher toughness compared to aluminum and magnesium alloys.

Improve car segment perception

Normally cars segments do not have formal characterization, but it is undoubted that boundaries between segments are blurred by other factors than the size or length of cars. These factors include price, image and the amount of extra accessories. Different kind of features work at the same time to get a perception about a segment to an end user. In order to have the ability to influence perception and get the end user attention zinc pressure die casting could be the solution. As said before zinc pressure die casting allows innovative shape and, thanks to its technical features, it also allows stunning finishing that could be the difference. A detail or a particular in car interior can make a jump in terms of cars segment perception.

Influence car driving experience

Considering that about 30% of the human decision process is based on visual information and that, according to many studies, products or components with high aesthetic grade are perceived to be easier to use than others that had less visual appeal. Following this idea it is important to develop and design car interiors with high values in terms of aesthetic features that help the end user. In fact, end users prefer simply, elegant and, above all, easy solution inside the car. Nowadays digitalization and innovation are really helpful in everyday life and can be really important in a car journey, but electronic devices can be complex to understand. According to researches designing car interiors with high aesthetic value makes simpler complex tools, helping end users to better understand functionalities and features. By using zinc, in terms of zinc pressure die casting, is possible to design car interiors accessories with high values in terms of aesthetic: useful for end users. Engineering capabilities help to design this kind of accessories.

As said zinc pressure die casting allows to add aesthetic values in car interior parts and improve perception. Thanks to its technical features zinc helps to develop different solutions, that could be a competitive advantage in the buyers journey to get the attention of end users.

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Following are some of the advantages that make zinc a strategic material when striving for cost reduction for a company that is active in the automotive sector.

These are factors to bear in mind when considering zinc as an option:

• Production costs
• Surface treatments
• Machining precision
• Technical characteristics
• Energy savings

Zinc Alloys in the Automotive Industry: how to save on costs?

Production costs

To achieve a large cost reduction during production it is essential to highlight three aspects: molds, methods and the higher speed of production of HPDC (hot chamber) processes.

Molds for zinc die casting, other than aluminum casting dies which usually have a limited life span, must provide hundreds of thousands of castings and often cover the full production cycle without need for specific maintenance that would negatively influence the final cost for the client. The cost can therefore be better amortized resulting in a lower unit cost.

In terms of machining costs, the possibility to achieve high degrees of precision translates directly into a lower number of production rejects. Regarding tolerances to be achieved, one major advantage of zinc die casting is the possibility to fully eliminate the machining process, therefore necessitating fewer operations after ejection of the product from the die.

Another advantage of hot chamber die casting compared to cold chamber casting is the cycle time. The hot chamber process provides improved control over temperature at high production volumes, the process is faster during the ejection of the product whilst in the cold chamber method there is less control over the temperature of the molten metal and therefore a lower molten metal productivity.

Today’s automotive industry uses zinc for many of its components, certainly the more complex components where machining of various different raw materials would be difficult, other than costly.

Surface treatments

Speaking of surface finish, die cast zinc can be subjected to various options of surface treatments:

• Galvanic chroming
• Gilding and silver plating
• Zinc plating
• Painting

Just to mention a few finishing methods that are relatively simple to apply to zinc alloys in the automotive industry, as opposed to aluminum, for instance.

The treatments can give an aesthetic result if the component is visible, or strictly functional if not exposed to view. The material is predisposed for finishing operations and requires less preparatory work, simplifying decorative and functional treatments as needed.

Casting precision

From the point of view of tolerances to be achieved, the results obtained by zinc die casting are mostly unobtainable with other materials, other than through much higher production costs that would be beyond market acceptance. Thin Wall Castability (up to 0,65 mm thickness) of zinc alloys allows to realize smaller, lighter components at much lower cost.

Technical characteristics

Zinc alloys are particularly versatile materials and unique from the point of view of strength, sturdiness, rigidity, resistance to wear and atmospheric agents.

Furthermore, the competitive cost compared to other materials contributes to making zinc an efficient choice for clients in many industrial environments. Thanks to the material’s fluidity, very thin walls are obtainable. Therefore aluminum, even with its lower specific weight, loses its competitiveness to zinc.

Machining surface treatments, polishing and finishing also cost much less on zinc components compared to similar surface treatments on brass components, for instance.

From the technical aspect die cast zinc has many advantages, such as:

• High resistance to traction
• High limit of conventional elasticity
• Resistance to alternate bending
• Hardness, sturdiness and corrosion resistance

Zinc die cast products offer higher resistance to shock and wear compared to components in other metals or plastics. Zinc products have a hardness comparable to cast iron and brass and corrosion resistance can be vastly improved with galvanic finishing processes such as zinc coating, chroming or nickel plating.

Energy savings

Cost reduction can also be obtained by focusing on energy consumption. A low melting temperature is another positive characteristic: zinc alloys require less energy for smelting and for casting the product.

The melting point for zinc for instance is about 410/420°C, allowing for a considerable saving in energy and a mold life span up to 10 times longer compared to aluminum. The lower temperatures minimize thermic shock and drastically reduce defects due to wear of the mold.

Focusing on the extremely minimal environmental impact, zinc and zinc alloys do not spread pollution or venomous substances. Production scrap can be easily reutilized, remolten with low energy consumption and efficiently recycled.

To achieve these benefits we like to stress the importance of consulting with an experienced die caster, who needs to have great technical knowledge to be able to suggest the best choices to the client in every phase of the development of a new project: from collaborating with the client during co-design phase to defining surface treatments to be applied at a later stage.

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