Zamak Alloys

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 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

PropertyMetricImperial
Density6.6 g/cm30.238lb/in3
Melting point1435 – 1446 degrees centigrade2615 – 2635 f

Mechanical properties

PropertiesMetricImperial
Shear strength360 MPa52213.5 psi
Tensile strength317 MPa45976.9 psi
Elongation at break7%7%
Brinell hardness100100

Thermal properties

PropertyMetricImperial
Thermal conductivity105 W/mK729 BTU.in/hrft².°F
Thermal expansion co-efficient27.8 µm/m°C15.4 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 elementContent in percentage (%)
Aluminum, Al3.8-4.2
Copper, Cu2.7-3.3
Magnesium, Mg0.035-0.06
Iron, Fe0.02
Silicon, Si0.02
Lead, Pb0.003
Cadmium, Cd0.003
Tin, Sn0.001
Nickel, Ni0.001

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 Alloy 2 Are Perfect For Industrial Fittings

 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

PropertyMetricImperial
Melting point381-387°C718-728°F
Density6.6 g/cm30.24 lb/in3

Mechanical properties

propertyMetricImperial
Tensile strength268 MPa38900 psi
Yield strength208 MPa30200 psi
Elasticity modulus96 GPa14000000 psi
Poisson’s ratio0.270.27
Elongation at break10%10%
Brinell hardness8282

Thermal properties

PropertyMetricImperial
Thermal conductivity113 W/mK65.3 BTU.in/hrft².°F
Thermal expansion co-efficient (@100-200°C/68-212°F)27.4, µm/m°C15.2 µin/in°F

Composition of Zamak 3 alloy

The following table shows the chemical composition.

Type of elementContent in percentage (%)
Aluminum, Al3.8 -4.2
Copper, Cu2.7 -3.3
Magnesium, Mg0.035 -0.06
Iron, Fe0.02
Silicon, Si0.02
Lead, Pb0.003
Cadmium, Cd0.003
Tin, Sn0.001
Nickel, Ni0.001

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

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

PropertyMetricImperial
Melting point380 -386°C717-727°F
Density6.6 g/cm30.24 lb/in3

Mechanical properties

PropertyMetricImperial
Tensile strength331 MPa48000 psi
Yield strength295 MPa43000 psi
Elasticity modulus96 GPa14000000 psi
Elongation of break7%7%
Brinell hardness9191

Thermal properties

PropertyMetricImperial
Thermal conductivity109 W/mK756 BTU.in/hrft².°F
Thermal expansion co-efficient27.4 µm/m°C15.2 µin/in°F

Composition Of Zamak 5 Alloy

The composition is illustrated below;

Type of elementContent 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, Mg0.010 – 0.080
Titanium, Ti0.010 – 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

 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

PropertyMetricImperial
Melting point381 -387°C718 -728°F
Density6.6 g/cm30.24 lb/in3

 Mechanical properties

PropertyMetricImperial
Tensile strength283 MPa441 psi
Yield strength221 MPa32 psi
Elongation at break13%13%
Brinell hardness8080

Thermal properties

PropertyMetric`imperial
Thermal conductivity113 W/mK784 BTU.in/hrft².°F
Thermal expansion co efficient27.4 µm/m°C15.2 µin/in°F

Composition Of Zamak 7 Alloy

The table below illustrates the chemical composition of Zamak 7 alloy

Type of elementContent in percentage (%)
Aluminum, Al3.8 -4.3
Copper, Cu0.25
Magnesium, Mg0.005 – 0.02
Iron, Fe0.075
Lead, Pb0.003
Cadmium, Cd0.002
Tin, Sn0.001
Nickel, Ni0.005 -0.02
Zinc, ZnRemainder

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.

PropertyMetricImperial
Density6.3 gm/cm30.227 lb/in3

Mechanical properties

PropertyMetricImperial
Tensile strength263 MPa38 ksi
Yield strength200 MPa29 ksi
Elasticity modulus85.5 GPa12400 ksi
Poisson’s ratio0.290.29

Composition Of Zamak 8 Alloy

ElementContent in percentage (%)
Aluminum, Al8.8
Copper, Cu1.3
Iron, Fe0.075
Magnesium, Mn0.03
Lead, Pb0.006
Cadmium, Cd0.006
Tin, Sn0.003
Zinc,ZnRemainder

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 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

PropertiesMetric
Melting range377 – 432 C
Density6.0 kg/dm3
Thermal expansion coefficient24.2 μm/m-°C
Thermal conductivity116.1 W/mK
Specific heat capacity448 J/kg-°C

Mechanical properties

PropertiesMetric
Compressive yield strength269 MPa
Elongation: % in 24 – 7
Fatigue strength117 MPa
Hardness95 – 115 Brinell
Impact strength29 J
Shear strength296 MPa
Tensile strength400 MPa
Yield strength (0.2 % offset)317 MPa

Composition Of Zamak 12 Alloy

The table below shows the composition of Zamak alloy 12

ElementAmount
Al10.8 – 11.5
Cu0.5 – 1.2
Mg0.02 – 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

PropertiesMetric
Specific weigh Kg/dm³6.60
Melting point lowest °C

Highest

380

386

Specific heat cal/g/°C0.098
Thermal conductivity at 20°C

Cal/sec/cm/°C

0.27
Resistivity μ Ω cm

Ω mm²/m

6,40

0,0640

Electrical conductivity at 20°C 1/ μ Ω cm

S m/mm²

0,157

15,7

Elastic modulus E Kg/mm²10.000
Coefficient of thermal expansion x 10¯⁶/°C27,4
Linear shrinkage %1,17
Maximum melting temperature °C480
Optimal range of pressure casting °C400 ÷ 440
Temperature of molds under pressure °C200

 Mechanical properties

PropertyMetric
Breaking load Kg/mm₂25 ÷ 28
Elongation %1,5
Brinell hardness Kg/mm²70 ÷ 85
Resilience Kgm/mm²2

 Composition Of Zamak 13 Alloy

ElementAmount
Al3.8 – 4.2
Cu≤ 0,03
Mg0,035 – 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.

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