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This article describes the control of alloy composition and impurity levels in die casting of zinc alloys based on agitation, use of foundry scrap, and melt temperature and fluxing. It reviews the process considerations for the melt processing of the zinc alloys. The process considerations include the usage of furnaces and launder system, scrap return, inclusions in zinc alloys, fluxing of zinc alloys, and galvanizing fluxes. The article discusses the materials and lubricant selection, casting and die temperature control, and trimming process used in hot chamber die casting for zinc alloys. It also reviews other casting processes for zinc alloys, such as sand casting, permanent mold casting, plaster mold casting, squeeze casting, and semisolid casting.

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