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Precision • Die Casting • Manufacturing

HOW MANY TYPES OF ZINC ALLOY MATERIALS ARE MOST COMMENLY USED?

Allwell Cast is a one of the best full service zinc die casting manufacturer for small and medium size products. We have produced millions of zinc die casting components—from paper thin size to 10 kilogram in weight.

Zinc Alloy Main Features:

  • Good thermal conductivity
  • Lower cost raw material
  • High accuracy on dimension and stability
  • High performance thin wall capability
  • High strength and hardness
  • Wonderful electrical conductivity
  • Capable to cold form, which helps joining
  • High quality surface finishing allowance
  • Excellent corrosion and acid resistance
  • Full recyclability

All the strength and hardness features of zinc allow itself to many more applications and it is the most suitable material for machined, pressed, fabricated and stamped spare parts or components.

Zinc Applications:

  • Complicated net-shaped metal shells, with high precision thin walls provide wonderful electrical performance and shielding functions.
  • Our exclusive multi-slide die casting techniques and special thin-wall capabilities able us one of the most advanced suppliers of zinc alloy spare parts for wide range of consumer electronic products and devices.
  • The characteristics of zinc such as wear resistance, and structural integrity able it the best choice for the needs of the multi-faceted, complicated shaped components in automotive and electronics industry.
zinc alloy products applications

 

Commenly Used Types of Zinc Alloy Materials



ZAMAK 2

Zinc Alloy 2, also called as Kirksite or Zamak 2 (ASTM AC43A), is with the strongest hardness and strength among the ZINC family. It has wonderful casting features including:

MECHANICAL features:

MaterialYield Strength (0.2%) Shear Strength Impact Strength Tensile Strength Elongation Hardness Process
Zamak 2PSI x 103PSI x 103ft lbPSI x 103% in 50mmBrinell (HB) 
Zinc Casting Metals414635527100Hot Chamber Die Casting

PHYSICAL FEATURES

MaterialAlloyCoefficient of Thermal Expansion Electrical Conductivity Melting Point (Average +/- 50) Density Thermal Conductivity Process
  µin/in°F%IACS°Flb/in3BTU/h∙ft∙°F 
Zinc Casting MetalsZamak 215.425.07250.24060.5Hot Chamber Die Casting

COMPOSITION

 ZINC alloy material
%Zamak 2
Aluminum3.5-4.3
Magnesium0.02-0.05
Copper2.5-3.0
Lead (max)0.005
Iron (max)0.1
Tin (max)0.003
Cadmium (max)0.004
ZincBal.
Nickel (max) 
Silicon 
Manganese 
Other-Metallic 
RoHS Compliant

ZAMAK 3

Zamak 3 also named as (ASTM AG40A), or Zinc Alloy 3, is the one of the most widely used zinc alloy materials worldwide and is often the first choice for many reasons:

  • Perfect balanced performance of wanted physical and mechanical features
  • Higher casting capability and dimensional stability for long-term usage
  • Superb outlook surface finishing features for chrome plating, painting, and chromate treatments
  • Higher damping ability and vibration attenuation compared with aluminum die casting material

When mentioning die castings, all the other zinc alloys should be rated for all kinds of standards based on ZAMAK 3 features.

MECHANICAL CHARACTERISTICS
MaterialAlloyShear Strength Impact Strength Hardness Yield Strength (0.2%) Tensile Strength Elongation Process
  PSI x 103ft lbBrinell (HB)PSI x 103PSI x 103% in 50mm 
Zinc AlloyZamak 3314382324110Hot Chamber Die Casting
PHYSICAL CHARACTERISTICS
 

 

aterial

AlloyMelting Point (Average +/- 50) Electrical Conductivity Density Thermal Conductivity Coefficient of Thermal Expansion Process
  °F%IACSlb/in3BTU/h∙ft∙°Fµin/in°F 
Zinc AlloyZamak 372327.00.24065.315.2Hot Chamber Die Casting
COMPOSITION of zamak 3
 ZINC CASTING METALS
%Zamak 3
Aluminum3.5-4.3
Copper0.25
Iron (max)0.1
Magnesium0.02-0.05
Cadmium (max)0.004
Tin (max)0.003
Lead (max)0.005
Nickel (max) 
ZincBal.
Manganese 
Silicon 
Other-Metallic 
RoHS Compliant
  

ZAMAK 5

Zamak 5 also called ASTM, AC41A or Zinc Alloy 5, is also one of the most widely used zinc alloy in many countries.

  • Higher copper content scale than Zamak 3, which results in better strength
  • Less decreased elongation than Zamak 3
  • Engineers must pay attention to that this less decreased elongation ability will affect formability in all the secondary operations such as riveting, bending, swaging, or crimping processes.
  • Thanks to the wide range of capabilities of Zamak 3, engineers often strengthen spare parts by design modifications instead of using Zamak 5 directly.
  • When tensile performance is needed for a component, Zamak 5 castings are recommended.
  • Zamak 5 is more readily made, finished, and processed than Alloy 3.
MECHANICAL FEATURES
MaterialAlloyShear Strength Tensile Strength Impact Strength Hardness Elongation Yield Strength (0.2%) Process
  PSI x 103PSI x 103ft lbBrinell (HB)% in 50mmPSI x 103 
Zinc Casting MetalsZamak 538484891733Hot Chamber Die Casting
PHYSICAL FEATURES
MaterialAlloyCoefficient of Thermal Expansion Thermal Conductivity Electrical Conductivity Density Melting Point (Average +/- 50) Process
  µin/in°FBTU/h∙ft∙°F%IACSlb/in3°F 
Zinc Casting MetalsZamak 515.262.926.00.240722Hot Chamber Die Casting
COMPOSITION
 ZINC CASTING METALS
%Zamak 5
Aluminum3.5-4.3
Copper0.75-1.25
Magnesium0.03-0.08
Iron (max)0.1
Lead (max)0.005
Cadmium (max)0.004
Tin (max)0.003
Nickel (max) 
ZincBal.
Manganese 
Silicon 
Other-Metallic 
RoHS Compliant

ZAMAK 7

Zamak 7 also known as ASTM, AG40B, or Zinc Alloy 7, is a modification version of Zamak 3.

It is a highly purified alloy, which contains lower magnesium and has a higher level of impurities features. This offers to the components with improved casting fluidity, ductility and surface finish effect.

Ideal Applications for Zamak 7

Zamak 7 is mostly needed for special hardware, or when castings request higher formability in the following assembly process such as crimping or staking. Moreover, its better fluidity allows thinner walls to be cast such as 5G optical module outer housing.

  • Sometimes, higher fluidity is very important especially for components with intricate details, but it do require special casting considerations and techniques.
  • In order to have better finishing surface and to avoid excessive flashings along the tool parting lines, perfect die fit and better close control of casting parameters are necessary.
  • The high ductility also has an impact on finished components, but mainly in subsequent processes for flash removal or trimming.
  • Zamak 7 shows superb damping ability and vibration attenuation compared with aluminum die casting alloys.
MECHANICAL FEATURES
MaterialAlloyElongation Yield Strength (0.2%) Shear Strength Hardness Tensile Strength Impact Strength Process
  % in 50mmMPaMPaBrinell (HB)MPaJ 
Zinc Casting MetalsZamak 7132212148028358Hot Chamber Die Casting
PHYSICAL PROPERTIES
MaterialAlloyThermal Conductivity Density Coefficient of Thermal Expansion Melting Point (Average +/- 50) Electrical Conductivity Process
  W / m Kg/cm3µm/m°K°C% IACS 
Zinc Casting MetalsZamak 71136.6027.438427.0Hot Chamber Die Casting
COMPOSITION
 ZINC CASTING METALS
%Zamak 7
Aluminum3.5-4.3
Copper0.25
Magnesium0.005-0.02
Iron (max)0.075
Lead (max)0.003
Cadmium (max)0.002
Tin (max)0.001
ZincBal.
RoHS Compliant

ZA 8

ZA-8, also called zinc aluminum alloy, contains more aluminum content than all the other Zamak group of alloys.

It has approximately 8.4% aluminum and is the only ZA alloy that can be used for hot-chamber die casting, which is an important consideration when and engineer selects materials for a component.

  • ZA-8 has superb finishing and plating features and was originally developed as a permanent mold alloy.
  • It is the best choice for decorative applications.
  • Even though it does not have as good casting features as the other zinc alloys, it provides significantly improved strength, hardness, and creep properties.
  • Regarding to mechanical performance, ZA 8 has the best creep strength of any zinc alloy and the highest strength of any hot-chamber die cast zinc alloy materials.
MECHANICAL FEATURES
MaterialAlloyElongation Yield Strength (0.2%) Shear Strength Tensile Strength Impact Strength Hardness Process
  % in 50mmPSI x 103PSI x 103PSI x 103ft lbBrinell (HB) 
Zinc Casting MetalsZA 81042405431103Hot Chamber Die Casting
PHYSICAL FEATURES
MaterialAlloyCoefficient of Thermal Expansion Density Thermal Conductivity Melting Point (Average +/- 50) Electrical Conductivity Process
  µin/in°Flb/in3BTU/h∙ft∙°F°F%IACS 
Zinc Casting MetalsZA 812.90.22766.373327.7Hot Chamber Die Casting
COMPOSITION
 ZINC CASTING METALS
%ZA 8
Aluminum8.0-8.8
Copper0.8-1.3
Magnesium0.015-0.03
Iron (max)0.075
Lead (max)0.006
Cadmium (max)0.006
Tin (max)0.003
Nickel (max) 
ZincBal.
Manganese 
Silicon 
Other-Metallic 
RoHS Compliant

ACUZINC5

This is a kind of alloy developed by General Motors.

  • It has significantly improved strength, hardness, and creep performance thanks to its higher copper and lower aluminum contents
  • Also can be called zinc copper aluminum alloy, has excellent bearing features like lubricity.
MECHANICAL FEATURES
MaterialAlloyYield Strength (0.2%) Hardness Elongation Tensile Strength Process
  MPaBrinell (HB)% in 50mmMPa 
Zinc Casting MetalsACuZinc53381155407Hot Chamber Die Casting
PHYSICAL FEATURES
MaterialAlloyCoefficient of Thermal Expansion Density Electrical Conductivity Melting Point (Average +/- 50) Thermal Conductivity Process
  µm/m°Kg/cm3% IACS°CW / m K 
Zinc Casting MetalsACuZinc524.16.8526.9452106Hot Chamber Die Casting
COMPOSITION
 ZINC CASTING METALS
%ACuZinc5
Aluminum2.8-3.3
Copper5.0-6.0
Magnesium0.025-0.05
Iron (max)0.075
Lead (max)0.005
Cadmium (max)0.004
Tin (max)0.003
ZincBal.
RoHS Compliant

ZA 27 – ZINC ALUMINUM

ZA-27 (zinc aluminum alloy) contains more aluminum than all the other Zamak group of alloys. The number 27 means the approximate percentage of aluminum.

  • ZA-27 contains the highest aluminum material, highest melting point, highest strength, and lowest density among the ZA group.
  • ZA-27 offers excellent bearing features, which allow bearings to be designed into the casting in some applications.
  • It needs the cold-chamber process because of its relatively higher casting temperature.
MECHANICAL FEATURES
MaterialAlloyImpact Strength Elongation Shear Strength Tensile Strength Yield Strength (0.2%) Hardness Process
  J% in 50mmMPaMPaMPaBrinell (HB) 
Zinc Casting MetalsZA 27 – Zinc Aluminum12.83325425376119Cold Chamber Die Casting
PHYSICAL FEATURES
MaterialAlloyThermal Conductivity Density Electrical Conductivity Melting Point (Average +/- 50) Coefficient of Thermal Expansion Process
  W / m Kg/cm3% IACS°Cµm/m°K 
Zinc Casting MetalsZA 27 – Zinc Aluminum1235.0029.743126.0Cold Chamber Die Casting
COMPOSITION
 ZINC CASTING METALS
%ZA 27 – Zinc Aluminum
Aluminum25.0-28.0
Copper2.0-2.5
Magnesium0.01-0.02
Iron (max)0.075
Lead (max)0.006
Cadmium (max)0.006
Tin (max)0.003
ZincBal.
RoHS Compliant

In general, the above are the material categories of zinc alloys frequently used in industrial production.

Allwell cast has focused on zinc alloy die-casting for more than 20 years, using environmentally friendly zinc alloy materials to ensure product quality. From design, die-casting, appearance processing, Allwell cast is your trusted partner as a zinc alloy die-casting manufacturer.

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