Core Applications of Aluminum/Zinc Alloy Die Castings in The Power And Telecommunications Industries

In the neural network of modern society comprised of power transmission and intelligent communication, the stability, efficiency, and reliability of every piece of equipment are crucial. Aluminum and zinc alloy die castings, as precision structural components within these high-end devices, are fundamental to ensuring their superior performance.

I. Power Industry: Power equipment typically faces severe challenges from high voltage, high current, complex electromagnetic environments, and harsh outdoor conditions. Aluminum die castings, with their unique properties, perfectly meet these demanding requirements.

Aluminum/zinc alloy die castings are commonly used in:

1. Smart Meters and Electricity Information Acquisition Systems

Application Components: Meter housing, bracket, current transformer housing, terminal blocks.

1) Electromagnetic Shielding: Aluminum and zinc alloys possess excellent electromagnetic shielding properties, effectively protecting the internal precision integrated circuits from external electromagnetic interference, ensuring the accuracy of data acquisition and transmission.

2) Heat Dissipation: The excellent thermal conductivity of aluminum alloys helps dissipate the heat generated during meter operation quickly, preventing damage from overheating and extending the equipment's service life.

3) Structural Strength and Sealing: The integrated housing, formed by die casting, is robust and can withstand certain mechanical impacts. Through precise fitting, it achieves IP54 or higher dust and water resistance, adapting to diverse outdoor environments.

Core advantages of aluminum/zinc alloy die castings: High precision, integrated molding, good heat dissipation and electromagnetic shielding, and excellent sealing protection.

2. Circuit Breakers & Distribution Switches

Application Components: Operating mechanism housing, arc-extinguishing chamber components, terminal blocks, transmission components.

1) High Strength and Wear Resistance: Zinc alloys possess extremely high mechanical strength and hardness, making them ideal for manufacturing transmission components and mechanism housings within circuit breakers that require frequent mechanical operation and wear resistance, ensuring accurate and reliable opening and closing actions.

2) Dimensional Stability: Die-cast parts maintain dimensional stability even at high temperatures and under long-term use, which is crucial for ensuring precise distances and insulation performance between switch contacts.

3) Flame Retardancy: By selecting appropriate alloy materials, the flame retardancy requirements of the equipment can be met.

Core advantages of aluminum/zinc alloy die castings: extremely high structural strength, excellent wear resistance, outstanding dimensional stability, and the ability to form complex thin-walled structures.

3. New Energy Charging Piles & Inverters

Application Components: Charging pile housings, power module heat dissipation bases, connector housings.

1) Structural Integration and Lightweighting: Aluminum alloy die casting allows multiple parts to be integrated into a single complex component, reducing assembly steps and achieving lightweighting while maintaining strength, facilitating installation and transportation.

2) Efficient Heat Dissipation: For high-power charging piles and inverters, aluminum alloy die-cast heat dissipation housings (such as heat sinks) are one of the optimal solutions for heat management.

3) Aesthetics and Durability: Die-cast housings have high surface quality, are easy to treat with surface treatments such as spraying, and can achieve an aesthetically pleasing and corrosion-resistant appearance, meeting the needs of public spaces.

Core advantages of aluminum/zinc alloy die castings: lightweight design, excellent heat dissipation capacity, high degree of design freedom, and good aesthetic texture.

II. Communications/Telecommunications Field: The rapid development of 5G, data centers, and fiber-to-the-home (FTTH) has placed high demands on communication equipment, requiring high density, high heat dissipation, high shielding, and miniaturization.

Aluminum/zinc alloy die-casting parts are commonly used in:

1. 5G Base Stations & Antenna Systems

Application Components: Antenna elements, filter cavities, base station structural components, heat sink housings.

1) Signal Integrity (Antenna Elements): Zinc alloy die-cast antenna elements are characterized by high precision, good consistency, and stable electrical performance, making them key components for achieving stable signal radiation. Their surfaces can be directly plated to ensure signal transmission efficiency.

2) Lightweighting and Heat Dissipation (Heat Sink Housing/Cavity): Aluminum alloy is an ideal material for manufacturing large heat sink housings and filter cavities for base stations, effectively reducing overall weight while maximizing heat dissipation area through complex internal structural design.

3) Cavity Precision (Filters): High-precision die-cast cavities ensure the stability of the filter's resonant frequency, which is crucial for signal quality.

The core advantages of aluminum/zinc alloy die castings: high RF performance, excellent thermal conductivity, lightweight structure, and consistency in mass production.

2. Optical Communication Equipment

Application Components: Fiber optic connector flanges, transceiver module housings, splitter enclosures.

1) High Precision and Stability: Zinc alloy die castings achieve micron-level precision, making them ideal for manufacturing fiber optic connector flanges with extremely high requirements for fiber core positioning, ensuring low-loss optical signal transmission.

2) Electromagnetic Shielding and Protection: Provides comprehensive electromagnetic shielding and physical protection for optical modules, preventing interference to internal lasers and chips.

3) Miniaturization: Die casting is ideal for producing complex, thin-walled, and tiny communication devices, meeting the trend of increasingly miniaturized equipment.

The core advantages of aluminum/zinc alloy die castings: extremely high dimensional accuracy, excellent electromagnetic shielding, and meeting the requirements of miniaturized complex structures.

3. Data Center Servers & Switches

Application Components: Hard drive brackets, chip heat sinks, I/O interface panels, structural frames.

1) Structural Rigidity: Ensures overall structural stability of servers during multi-layer stacking and plugging/unplugging.

2) Efficient Heat Dissipation: Die-cast aluminum alloy CPU heatsinks and chip bases are the core of data center cooling systems.

3) Vibration Damping and Protection: Provides robust support and vibration damping protection for delicate hard drives and motherboards.

Core Advantages of Aluminum/Zinc Alloy Die Castings: High rigidity, excellent thermal conductivity, production efficiency, and cost control.

With technological advancements, the prospects for aluminum/zinc alloy die castings in the power and communications fields will be even broader:

Integration and Functional Integration: 

Future die castings will not only be structural components but also "intelligent" parts integrating heat dissipation channels, electromagnetic shielding, conductive paths, and sensing functions.

Advances in Materials Science: 

New alloys with high thermal conductivity, high strength, and greater cost-effectiveness will be developed to adapt to higher power densities and more demanding application environments.

Combination with Additive Manufacturing: 

3D-printed die casting molds will enable freer and more optimized complex internal flow channel and lightweight structural designs, further improving product performance.

Green and Sustainable Development: 

The use of recycled aluminum/zinc alloys and more environmentally friendly surface treatment processes will become industry standards, responding to global carbon neutrality goals.

We have deep expertise in aluminum and zinc alloy die casting, possessing comprehensive capabilities from mold design and precision die casting to post-processing and testing. We deeply understand the technological needs of the power and communications industries and are committed to providing customers with one-stop solutions from material selection and structural optimization to mass production delivery.