Zinc die-casting: recycling, applications and market potential
Teaser
Zinc die-casting remains relevant for many industrial applications because the material combines castability, electrical conductivity and recyclability. Martin van Leeuwen from the International Zinc Association outlines the role that zinc alloys play in electrification, the circular economy and sustainable manufacturing.
Zinc die-casting: demand, applications and competition
According to the International Zinc Association, zinc alloys are set to see a growing range of applications. Martin van Leeuwen, Director of Technology and Market Development at the IZA, refers to a recent market report which forecasts rising demand for zinc die-casting up to 2035. The source text cites technological advances, demographic trends, electromobility, urbanisation and growing consumer markets in the middle-income segment as key influencing factors.
Applications in electrification and renewable energy
Electrification is a key driver for additional areas of application. According to the source text, die-cast zinc components are increasingly being used in connectors for electrical and signal cables, sensor housings and other electrical systems. Zinc components are also found in solar installations, for example as brackets and clamps in mounting systems.
The material combines castability with electrical and thermal conductivity. As the article explains, this makes zinc suitable for electrical components and processing units. Van Leeuwen also highlights the material’s corrosion resistance. For applications in harsh environmental conditions, zinc castings can be protected by electroplated metal surfaces or organic coating systems. Visible components can also be given a decorative finish, for example on door handles, shower fittings, taps, zips or watches.
Recycling strengthens zinc’s role in the circular economy
The source text places particular emphasis on recycling. Recycled zinc is described as an increasingly important source for meeting global demand. Whilst primary zinc production has remained relatively stable, the documented volume of recovered zinc has risen from around three million tonnes in 2010 to approximately five to six million tonnes today. At the same time, van Leeuwen points out that informal recycling activities in several countries are not fully reflected in official statistics.
The quality of the secondary material is crucial for industrial use. According to van Leeuwen, modern upcycling technologies can restore recycled zinc to a high degree of purity. In practice, zinc recycling usually involves remelting and, where necessary, additional refining steps. Compared with the production of primary zinc from ore, remelting requires significantly less energy and results in a considerably lower carbon footprint, according to the source text.
Secondary ZAMAK as an example of resource-efficient alloys
ZAMAK refers to zinc-based alloys containing aluminium, magnesium and, depending on the grade, copper. According to the source text, the International Zinc Association has carried out a life-cycle assessment of ZAMAK alloys made from recycled zinc. According to the IZA, this was the first study to focus specifically on secondary ZAMAK alloys.
The analysis covered around 76 per cent of the production of secondary ZAMAK alloys in the European Union and utilised operational data from participating manufacturers. According to the article, secondary ZAMAK alloys exhibited a lower environmental impact than primary alloys across all environmental indicators assessed. The main reasons cited are lower energy consumption and reduced use of new raw materials.
Efficiency in the die-casting process
Zinc die-casting competes with aluminium, brass, engineering plastics and extruded metal products. The source text lists several manufacturing advantages: zinc die-cast components generally require only minimal post-processing after casting, such as minor turning and trimming. This can reduce production time and material waste.
In addition, zinc’s comparatively low melting temperature and the short cycle times of die-casting machines contribute to efficient production. According to the article, zinc is particularly valued in the die-casting industry for high-precision, thin-walled micro-castings. At the same time, competition from alternative materials remains a challenge. Van Leeuwen therefore emphasises the importance of innovation and cost competitiveness for further development.
Key facts at a glance:
- According to its latest market report, the International Zinc Association expects demand for zinc die-casting to rise until 2035.
- New applications are emerging in areas such as electric vehicles, electrical systems and solar installations.
- Recycled zinc and secondary ZAMAK are becoming increasingly important for the circular economy and resource efficiency.
FAQ
According to the source text, zinc die-cast components are used in connectors, sensor housings and other electrical systems. Solar installations also utilise zinc components in mounting systems.
Recycled zinc can be remelted and refined to make it suitable for use in demanding applications once again. According to the source text, the process requires less energy than the production of primary zinc from ore.
Secondary ZAMAK refers to ZAMAK alloys based on recycled zinc. ZAMAK combines zinc with aluminium, magnesium and, depending on the alloy type, copper.
