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.

 

Commenly Used Types of Zinc Alloy Materials

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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:

• A better creep performance
• Higher damping capability and vibration attenuation capacity compared with aluminum die casting
• Higher strength and hardness after long-time using

MECHANICAL features:

Material	Yield Strength (0.2%)	Shear Strength	Impact Strength	Tensile Strength	Elongation	Hardness	Process
Zamak 2	PSI x 103	PSI x 103	ft lb	PSI x 103	% in 50mm	Brinell (HB)
Zinc Casting Metals	41	46	35	52	7	100	Hot Chamber Die Casting

PHYSICAL FEATURES

Material	Alloy	Coefficient of Thermal Expansion	Electrical Conductivity	Melting Point (Average +/- 50)	Density	Thermal Conductivity	Process
		µin/in°F	%IACS	°F	lb/in3	BTU/h∙ft∙°F
Zinc Casting Metals	Zamak 2	15.4	25.0	725	0.240	60.5	Hot Chamber Die Casting

COMPOSITION

	ZINC alloy material
%	Zamak 2
Aluminum	3.5-4.3
Magnesium	0.02-0.05
Copper	2.5-3.0
Lead (max)	0.005
Iron (max)	0.1
Tin (max)	0.003
Cadmium (max)	0.004
Zinc	Bal.
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

Material	Alloy	Shear Strength	Impact Strength	Hardness	Yield Strength (0.2%)	Tensile Strength	Elongation	Process
		PSI x 103	ft lb	Brinell (HB)	PSI x 103	PSI x 103	% in 50mm
Zinc Alloy	Zamak 3	31	43	82	32	41	10	Hot Chamber Die Casting

PHYSICAL CHARACTERISTICS

aterial	Alloy	Melting Point (Average +/- 50)	Electrical Conductivity	Density	Thermal Conductivity	Coefficient of Thermal Expansion	Process
		°F	%IACS	lb/in3	BTU/h∙ft∙°F	µin/in°F
Zinc Alloy	Zamak 3	723	27.0	0.240	65.3	15.2	Hot Chamber Die Casting

COMPOSITION of zamak 3

	ZINC CASTING METALS
%	Zamak 3
Aluminum	3.5-4.3
Copper	0.25
Iron (max)	0.1
Magnesium	0.02-0.05
Cadmium (max)	0.004
Tin (max)	0.003
Lead (max)	0.005
Nickel (max)
Zinc	Bal.
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

Material	Alloy	Shear Strength	Tensile Strength	Impact Strength	Hardness	Elongation	Yield Strength (0.2%)	Process
		PSI x 103	PSI x 103	ft lb	Brinell (HB)	% in 50mm	PSI x 103
Zinc Casting Metals	Zamak 5	38	48	48	91	7	33	Hot Chamber Die Casting

PHYSICAL FEATURES

Material	Alloy	Coefficient of Thermal Expansion	Thermal Conductivity	Electrical Conductivity	Density	Melting Point (Average +/- 50)	Process
		µin/in°F	BTU/h∙ft∙°F	%IACS	lb/in3	°F
Zinc Casting Metals	Zamak 5	15.2	62.9	26.0	0.240	722	Hot Chamber Die Casting

COMPOSITION

	ZINC CASTING METALS
%	Zamak 5
Aluminum	3.5-4.3
Copper	0.75-1.25
Magnesium	0.03-0.08
Iron (max)	0.1
Lead (max)	0.005
Cadmium (max)	0.004
Tin (max)	0.003
Nickel (max)
Zinc	Bal.
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

Material	Alloy	Elongation	Yield Strength (0.2%)	Shear Strength	Hardness	Tensile Strength	Impact Strength	Process
		% in 50mm	MPa	MPa	Brinell (HB)	MPa	J
Zinc Casting Metals	Zamak 7	13	221	214	80	283	58	Hot Chamber Die Casting

PHYSICAL PROPERTIES

Material	Alloy	Thermal Conductivity	Density	Coefficient of Thermal Expansion	Melting Point (Average +/- 50)	Electrical Conductivity	Process
		W / m K	g/cm3	µm/m°K	°C	% IACS
Zinc Casting Metals	Zamak 7	113	6.60	27.4	384	27.0	Hot Chamber Die Casting

COMPOSITION

	ZINC CASTING METALS
%	Zamak 7
Aluminum	3.5-4.3
Copper	0.25
Magnesium	0.005-0.02
Iron (max)	0.075
Lead (max)	0.003
Cadmium (max)	0.002
Tin (max)	0.001
Zinc	Bal.
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

Material	Alloy	Elongation	Yield Strength (0.2%)	Shear Strength	Tensile Strength	Impact Strength	Hardness	Process
		% in 50mm	PSI x 103	PSI x 103	PSI x 103	ft lb	Brinell (HB)
Zinc Casting Metals	ZA 8	10	42	40	54	31	103	Hot Chamber Die Casting

PHYSICAL FEATURES

Material	Alloy	Coefficient of Thermal Expansion	Density	Thermal Conductivity	Melting Point (Average +/- 50)	Electrical Conductivity	Process
		µin/in°F	lb/in3	BTU/h∙ft∙°F	°F	%IACS
Zinc Casting Metals	ZA 8	12.9	0.227	66.3	733	27.7	Hot Chamber Die Casting

COMPOSITION

	ZINC CASTING METALS
%	ZA 8
Aluminum	8.0-8.8
Copper	0.8-1.3
Magnesium	0.015-0.03
Iron (max)	0.075
Lead (max)	0.006
Cadmium (max)	0.006
Tin (max)	0.003
Nickel (max)
Zinc	Bal.
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

Material	Alloy	Yield Strength (0.2%)	Hardness	Elongation	Tensile Strength	Process
		MPa	Brinell (HB)	% in 50mm	MPa
Zinc Casting Metals	ACuZinc5	338	115	5	407	Hot Chamber Die Casting

PHYSICAL FEATURES

Material	Alloy	Coefficient of Thermal Expansion	Density	Electrical Conductivity	Melting Point (Average +/- 50)	Thermal Conductivity	Process
		µm/m°K	g/cm3	% IACS	°C	W / m K
Zinc Casting Metals	ACuZinc5	24.1	6.85	26.9	452	106	Hot Chamber Die Casting

COMPOSITION

	ZINC CASTING METALS
%	ACuZinc5
Aluminum	2.8-3.3
Copper	5.0-6.0
Magnesium	0.025-0.05
Iron (max)	0.075
Lead (max)	0.005
Cadmium (max)	0.004
Tin (max)	0.003
Zinc	Bal.
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

Material	Alloy	Impact Strength	Elongation	Shear Strength	Tensile Strength	Yield Strength (0.2%)	Hardness	Process
		J	% in 50mm	MPa	MPa	MPa	Brinell (HB)
Zinc Casting Metals	ZA 27 – Zinc Aluminum	12.8	3	325	425	376	119	Cold Chamber Die Casting

PHYSICAL FEATURES

Material	Alloy	Thermal Conductivity	Density	Electrical Conductivity	Melting Point (Average +/- 50)	Coefficient of Thermal Expansion	Process
		W / m K	g/cm3	% IACS	°C	µm/m°K
Zinc Casting Metals	ZA 27 – Zinc Aluminum	123	5.00	29.7	431	26.0	Cold Chamber Die Casting

COMPOSITION

	ZINC CASTING METALS
%	ZA 27 – Zinc Aluminum
Aluminum	25.0-28.0
Copper	2.0-2.5
Magnesium	0.01-0.02
Iron (max)	0.075
Lead (max)	0.006
Cadmium (max)	0.006
Tin (max)	0.003
Zinc	Bal.
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.