These are alloys that consists a zinc base and alloying comprising of magnesium, copper and aluminium.
They are resistant alloys that are easy to work with.
It has a stainless characteristic thus making it ideal for die castings and also their fluidity makes it possible to produce parts in large quantities.
Mostly, Zamak alloys are used in mechanical constructions, automotive industry, furniture, jewellery and much more.
Let’s learn more about these alloys.
Types Of Zamak Alloys
Zamak Are Alloys With A Zinc Base
Zamak 2 Alloy
Among the zinc alloys, Zamak 2 alloy is the highest in hardness and strength of the Zamak alloys family.
Some of the excellent casting characteristics the alloy has includes the following;
When it comes to performance, a higher creep is witnessed compared to the other types of Zamak alloys.
Compared to aluminum cast alloys, it has excellent vibration attenuation and a dumping capacity that is excellent.
It has high levels of hardness and high strength after an aging that is long term.
Properties Of Zamak 2 Alloy
Below are the physical, mechanical and thermal properties of Zamak 2 alloy.
Physical properties
| Property | Metric | Imperial |
| Density | 6.6 g/cm3 | 0.238lb/in3 |
| Melting point | 1435 – 1446 degrees centigrade | 2615 – 2635 f |
Mechanical properties
| Properties | Metric | Imperial |
| Shear strength | 360 MPa | 52213.5 psi |
| Tensile strength | 317 MPa | 45976.9 psi |
| Elongation at break | 7% | 7% |
| Brinell hardness | 100 | 100 |
Thermal properties
| Property | Metric | Imperial |
| Thermal conductivity | 105 W/mK | 729 BTU.in/hrft².°F |
| Thermal expansion co-efficient | 27.8 µm/m°C | 15.4 µin/in°F |
Composition Of Zamak 2 Alloy
Zamak 2 alloy is made up of the following constituents with the respective content percentages.
| Type of element | Content in percentage (%) |
| Aluminum, Al | 3.8-4.2 |
| Copper, Cu | 2.7-3.3 |
| Magnesium, Mg | 0.035-0.06 |
| Iron, Fe | 0.02 |
| Silicon, Si | 0.02 |
| Lead, Pb | 0.003 |
| Cadmium, Cd | 0.003 |
| Tin, Sn | 0.001 |
| Nickel, Ni | 0.001 |
Benefits Of Zamak 2 Alloy
Performance wise, Zamak 2 alloy shows a high creep compared to the other types of alloys.
Since it possesses a high creep, it gives it the ability to contain pressure under the implemented load during the die process of die casting.
Also, the alloy has a higher amount of copper that makes it so strong compared to the other types of Zamak alloys.
Items made from Zamak 2 alloy are strong because of the higher levels of copper in it.
Additionally, it contains vibration attenuation and damping capacity that are excellent compared to die cast alloys of aluminium.
Limitations Of Zamak 2 Alloy
Zamak 2 alloy is the most expensive alloy to use.
Despite having high levels of copper contents which makes it stronger, the alloy may not last long as intended to.
Uses Of Zamak 2 Alloy
Zamak 2 is used in a wide range of applications, some of its uses include the following;
Zamak 2 alloys are used in the metal forming dies.
The alloy is applied in the tools of plastic injection.
Zamak 2 alloys are used in the industrial fittings and gears.
Zamak 2 Alloys Are Perfect For Industrial Fittings And Gears
Zamak 3 Alloy
It is widely used in the zinc casting since it provides excellent finishing and plating characteristic.
Additionally, it is used widely used in zinc die casting because it has a great combination of ductility and strength.
Properties Of Zamak 3 Alloy
The following are the physical, mechanical and thermal properties.
Physical properties
| Property | Metric | Imperial |
| Melting point | 381-387°C | 718-728°F |
| Density | 6.6 g/cm3 | 0.24 lb/in3 |
Mechanical properties
| property | Metric | Imperial |
| Tensile strength | 268 MPa | 38900 psi |
| Yield strength | 208 MPa | 30200 psi |
| Elasticity modulus | 96 GPa | 14000000 psi |
| Poisson’s ratio | 0.27 | 0.27 |
| Elongation at break | 10% | 10% |
| Brinell hardness | 82 | 82 |
Thermal properties
| Property | Metric | Imperial |
| Thermal conductivity | 113 W/mK | 65.3 BTU.in/hrft².°F |
| Thermal expansion co-efficient (@100-200°C/68-212°F) | 27.4, µm/m°C | 15.2 µin/in°F |
Composition of Zamak 3 alloy
The following table shows the chemical composition.
| Type of element | Content in percentage (%) |
| Aluminum, Al | 3.8 -4.2 |
| Copper, Cu | 2.7 -3.3 |
| Magnesium, Mg | 0.035 -0.06 |
| Iron, Fe | 0.02 |
| Silicon, Si | 0.02 |
| Lead, Pb | 0.003 |
| Cadmium, Cd | 0.003 |
| Tin, Sn | 0.001 |
| Nickel, Ni | 0.001 |
Benefits Of Zamak 3 Alloy
It has excellent options for plating and finishing characteristics that are reliable hence making a good final end product that is more appealing.
It has a casting stability that is long term.
It has dumping capacity and vibration attenuation that are excellent as compared to the die cast alloys made of aluminium.
It has excellent balance of, mechanical properties and physical properties that make it superb for use.
It contains great combination of physical strength, ductility and impact strength.
Suitable for small- and large-scale productions.
Limitations Of Zamak 3 Alloy
The bending and hardness strengths of Zamak 3 decreases with an increase in the aging temperature.
Uses Of Zamak 3 Alloy
Zamak 3 alloys are used in the following areas;
- By plumbers when doing plumbing fittings
- They are used in the automotive industries
- You can use then in ceiling fans, blenders, zippers
A Zamak 3 Alloy Bathroom Faucet Tap Handle
Zamak 5 Alloy
The alloy has the same compositions with the Zamak 3 but there is and additional copper percentage to improve resistance, strength and hardness.
The increase of copper contents causes the alloy to reduce its ductility which affects the formality in bending, crimping and riveting operations.
Zamak 5 alloy is readily plated, machined and finished compared to the other types of alloys.
Properties Of Zamak 5 Alloy
Properties of Zamak 5 alloy are displayed I he tables below- the physical, mechanical and thermal properties.
Physical properties
| Property | Metric | Imperial |
| Melting point | 380 -386°C | 717-727°F |
| Density | 6.6 g/cm3 | 0.24 lb/in3 |
Mechanical properties
| Property | Metric | Imperial |
| Tensile strength | 331 MPa | 48000 psi |
| Yield strength | 295 MPa | 43000 psi |
| Elasticity modulus | 96 GPa | 14000000 psi |
| Elongation of break | 7% | 7% |
| Brinell hardness | 91 | 91 |
Thermal properties
| Property | Metric | Imperial |
| Thermal conductivity | 109 W/mK | 756 BTU.in/hrft².°F |
| Thermal expansion co-efficient | 27.4 µm/m°C | 15.2 µin/in°F |
Composition Of Zamak 5 Alloy
The composition is illustrated below;
| Type of element | Content in percentage (%) |
| Nickel, Ni | ≥99 |
| Manganese,Mn | ≤0.35 |
| Iron, Fe | ≤0.20 |
| Silicon, Si | ≤0.15 |
| Copper, Cu | ≤0.15 |
| Carbon, C | ≤0.15 |
| Magnesium, Mg | 0.010 – 0.080 |
| Titanium, Ti | 0.010 – 0.050 |
| Sulfur, S | ≤0.0080 |
Benefits Of Zamak 5
Being a strong and hard material, Zamak 5 alloy can withstand pressure that is exerted on it.
The property makes to be considered when it comes to security applications since it is not easy to break.
Also, it guarantees safety while using it, unlike materials like magnesium that might cause fire.
Additionally, it allows a casting that is complete and defect free thus producing items that are perfectly finished.
Moreover, it saves costs and time as other processing operations are reduced to the minimum.
Furthermore, the alloy remains clean as it does not get dirty like other materials such as silver.
Limitations Of Zamak 5 Alloy
Some of the limitations of Zamak 5 include the following;
The alloy is a poor resistant of humidity as it corrodes when exposed to wetness for some time.
When the alloy is subjected to higher temperatures, its tensile strength decreases thus making its parts to become fragile.
It is not suitable for lightweight applications since it yields thicker parts compared to the other non-ferrous alloys.
When mixed with metals like tin and lead, the resistance to corrosion s always compromised.
The impact properties fall remarkably if the alloy has been subjected to low temperatures.
Uses Of Zamak 5 Alloy
Zamak 5 alloy can be applied in the following areas;
The alloy is used in the die casting of toys.
Zamak 5 is used in the wheel balancing weights
The alloy is used in small engine and automotive applications.
Car Toys Made From Zamak 5 Alloys
Zamak 7 Alloy
This is a high purity alloy that contains low levels of magnesium and they have better ductility.
To reduce inter granular and to control impurities, little volumes of nickel are put to the alloy.
The alloy also possesses damping capacity and vibration as compared to aluminium alloys.
Properties Of Zamak 7 Alloy
Physical properties
| Property | Metric | Imperial |
| Melting point | 381 -387°C | 718 -728°F |
| Density | 6.6 g/cm3 | 0.24 lb/in3 |
Mechanical properties
| Property | Metric | Imperial |
| Tensile strength | 283 MPa | 441 psi |
| Yield strength | 221 MPa | 32 psi |
| Elongation at break | 13% | 13% |
| Brinell hardness | 80 | 80 |
Thermal properties
| Property | Metric | `imperial |
| Thermal conductivity | 113 W/mK | 784 BTU.in/hrft².°F |
| Thermal expansion co efficient | 27.4 µm/m°C | 15.2 µin/in°F |
Composition Of Zamak 7 Alloy
The table below illustrates the chemical composition of Zamak 7 alloy
| Type of element | Content in percentage (%) |
| Aluminum, Al | 3.8 -4.3 |
| Copper, Cu | 0.25 |
| Magnesium, Mg | 0.005 – 0.02 |
| Iron, Fe | 0.075 |
| Lead, Pb | 0.003 |
| Cadmium, Cd | 0.002 |
| Tin, Sn | 0.001 |
| Nickel, Ni | 0.005 -0.02 |
| Zinc, Zn | Remainder |
Benefits Of Zamak 7 Alloy
With Zamak 7 alloys, there is an option of casting thinner walls within the components hence intricate components can be produced.
Zamak 7 castings are always having improved ductility, surface finish and fluidity.
Limitations Of Zamak 7 Alloy
It is only suitable for thin walled components.
Uses Of Zamak 7 Alloy
It is used in the case where a die caster is employed to make components that are thin walled and require a good surface finish.
Zamak 8 Alloy
Zamak 8 alloy contains more aluminium than the other Zamak group of alloys.
It is the only alloy that can withstand the die cast of a hot chamber since it contains highest zinc creep strength.
Its plating and finishing characteristics are excellent as compared to the other alloys.
Properties Of Zamak 8 Alloy
Physical properties
The table below shows the physical properties of zamak 8 aloy.
| Property | Metric | Imperial |
| Density | 6.3 gm/cm3 | 0.227 lb/in3 |
Mechanical properties
| Property | Metric | Imperial |
| Tensile strength | 263 MPa | 38 ksi |
| Yield strength | 200 MPa | 29 ksi |
| Elasticity modulus | 85.5 GPa | 12400 ksi |
| Poisson’s ratio | 0.29 | 0.29 |
Composition Of Zamak 8 Alloy
| Element | Content in percentage (%) |
| Aluminum, Al | 8.8 |
| Copper, Cu | 1.3 |
| Iron, Fe | 0.075 |
| Magnesium, Mn | 0.03 |
| Lead, Pb | 0.006 |
| Cadmium, Cd | 0.006 |
| Tin, Sn | 0.003 |
| Zinc,Zn | Remainder |
Benefits Of Zamak 8 Alloy
The alloy has great plating and finishing features.
It provides significant improved levels of hardness, strength and creep properties.
Besides, it can undergo a hot chamber die cast.
It achieves high accuracy levels.
Limitations Of Zamak 8 Alloy
It has poor characteristics when it comes to casting, the other Zamak alloys are way better to use when casting.
Uses Of Zamak 8 Alloy
It is ideal for thin wall decorations.
Besides, it is used in die casting.
It is used in bearings.
Zamak 8 Alloy Is Ideal In The Manufacturing Of Thin Wall Decorations
Zamak 12 Alloy
It is a type of alloy that is desired in the permanent molding applications because of its tensile strength and hardness.
Properties Of Zamak 12 Alloy
The tables below are illustrating the properties respectively.
Physical properties
| Properties | Metric |
| Melting range | 377 – 432 C |
| Density | 6.0 kg/dm3 |
| Thermal expansion coefficient | 24.2 μm/m-°C |
| Thermal conductivity | 116.1 W/mK |
| Specific heat capacity | 448 J/kg-°C |
Mechanical properties
| Properties | Metric |
| Compressive yield strength | 269 MPa |
| Elongation: % in 2 | 4 – 7 |
| Fatigue strength | 117 MPa |
| Hardness | 95 – 115 Brinell |
| Impact strength | 29 J |
| Shear strength | 296 MPa |
| Tensile strength | 400 MPa |
| Yield strength (0.2 % offset) | 317 MPa |
Composition Of Zamak 12 Alloy
The table below shows the composition of Zamak alloy 12
| Element | Amount |
| Al | 10.8 – 11.5 |
| Cu | 0.5 – 1.2 |
| Mg | 0.02 – 0.03 |
| Pb | ≤0.005 |
| Fe | ≤0.05 |
| Cd | ≤0.005 |
| Sn | ≤0.002 |
| Si | ≤0.05 |
| Ni | ≤0.001 |
Benefits Of Zamak 12 Alloy
It has high levels of tensile strength and hardness.
Furthermore, it can provide best results even if it undergoes cold chamber die cast.
It can combine properties of high performance and ease of fabrication either using a die casting of pressure or gravity.
It is palatable.
Limitations Of Zamak 12 Alloy
The alloy is affected by stirring.
Uses Of Zamak 12 Alloy
It is used in permanent mold application processes.
Zamak 13 Alloy
Among the other alloys, this is the only alloy that has a great resistance behavior, and a higher dimensional stability when it comes to aging.
Properties Of Zamak 13
Physical properties
| Properties | Metric |
| Specific weigh Kg/dm³ | 6.60 |
| Melting point lowest °CHighest | 380386 |
| Specific heat cal/g/°C | 0.098 |
| Thermal conductivity at 20°CCal/sec/cm/°C | 0.27 |
| Resistivity μ Ω cmΩ mm²/m | 6,400,0640 |
| Electrical conductivity at 20°C 1/ μ Ω cmS m/mm² | 0,15715,7 |
| Elastic modulus E Kg/mm² | 10.000 |
| Coefficient of thermal expansion x 10¯⁶/°C | 27,4 |
| Linear shrinkage % | 1,17 |
| Maximum melting temperature °C | 480 |
| Optimal range of pressure casting °C | 400 ÷ 440 |
| Temperature of molds under pressure °C | 200 |
Mechanical properties
| Property | Metric |
| Breaking load Kg/mm₂ | 25 ÷ 28 |
| Elongation % | 1,5 |
| Brinell hardness Kg/mm² | 70 ÷ 85 |
| Resilience Kgm/mm² | 2 |
Composition Of Zamak 13 Alloy
| Element | Amount |
| Al | 3.8 – 4.2 |
| Cu | ≤ 0,03 |
| Mg | 0,035 – 0,060 |
| Pb | ≤ 0,0030 |
| Fe | ≤ 0,0200 |
| Cd | ≤ 0,0030 |
| Sn | ≤ 0,0010 |
| Si | ≤ 0,0200 |
| Ni | ≤ 0,0010 |
Benefits Of Zamak 13 Alloy
The alloy has a higher impact resistance and two-dimensional stability over time.
It has a high resistance to corrosion despite the weather ranges.
Limitations Of Zamak 13 Alloy
It is not preferred for thin-walled surfaces.
Uses Of Zamak 13 Alloy
It is used to die cast materials where the weather conditions are harsh for the ordinary alloys.
How Zamak Alloys Compere To Aluminum Alloys
Zamak alloys have a lower melting point as compared to aluminum alloys hence the production is less costly.
Casting precision of Zamak alloys is better since their strength is significantly higher as compared to aluminum alloys.
Zamak alloys are lighter in terms of weight while aluminum alloys are always heavier.
At Inox, we die cast all zinc alloys alongside other metals such as aluminum, magnesium, copper and titanium, just to mention a few.
For any questions or inquiry about Zamak alloys, contact us now.