Overview
Zamak 2 is a high-strength zinc die-casting alloy belonging to the Zamak family of zinc-aluminum alloys. It contains approximately 4% aluminum, 3% copper, and small amounts of magnesium, providing the highest strength and hardness among standard Zamak alloys.
Compared with Zamak 3 and Zamak 5, Zamak 2 offers superior mechanical properties, wear resistance, creep resistance, and bearing performance, making it ideal for precision die-cast components subjected to higher mechanical loads.
Zamak 2 is widely used in:
- Precision Die Cast Components
- Automotive Hardware
- Industrial Machinery Parts
- Lock Components
- Gears and Bearings
- Electrical Hardware
- Consumer Products
- Decorative Metal Components
Due to its excellent castability and high mechanical strength, Zamak 2 is often selected for applications requiring durable and dimensionally stable zinc castings.
Material Specification
| Property | Value |
|---|---|
| Material Designation | Zamak 2 |
| UNS Number | Z35530 |
| ASTM Standard | ASTM B86 |
| Material Family | Zinc-Aluminum-Copper Alloy |
| Density | 6.6 g/cm³ |
| Magnetic Property | Non-Magnetic |
| Typical Manufacturing Process | High Pressure Die Casting |
| Standard Forms | Die Cast Parts, Ingots |
Chemical Composition
| Element | Content (%) |
|---|---|
| Zinc (Zn) | Balance |
| Aluminum (Al) | 3.8–4.3 |
| Copper (Cu) | 2.7–3.3 |
| Magnesium (Mg) | 0.02–0.06 |
| Iron (Fe) | ≤0.075 |
| Lead (Pb) | ≤0.003 |
| Cadmium (Cd) | ≤0.003 |
| Tin (Sn) | ≤0.001 |
The increased copper content significantly improves strength, hardness, and wear resistance.
Mechanical Properties
As-Cast Condition
| Property | Value |
|---|---|
| Tensile Strength | 355–410 MPa |
| Yield Strength | 300–330 MPa |
| Elongation | 3–7% |
| Hardness | 110–130 HB |
| Elastic Modulus | 86 GPa |
Typical Mechanical Performance
| Property | Value |
|---|---|
| Fatigue Resistance | Good |
| Wear Resistance | Excellent |
| Creep Resistance | Excellent |
| Impact Strength | Good |
Physical Properties
| Property | Value |
|---|---|
| Density | 6.6 g/cm³ |
| Melting Range | 380–390°C |
| Thermal Conductivity | 113 W/m·K |
| Electrical Conductivity | 26% IACS |
| Electrical Resistivity | 0.064 μΩ·m |
| Thermal Expansion Coefficient | 27 × 10⁻⁶/K |
| Specific Heat Capacity | 420 J/kg·K |
Strength-to-Weight Ratio
| Material | Density (g/cm³) | Tensile Strength |
|---|---|---|
| Zamak 2 | 6.6 | 410 MPa |
| Zamak 3 | 6.6 | 283 MPa |
| Zamak 5 | 6.6 | 330 MPa |
| Aluminum A380 | 2.73 | 325 MPa |
Zamak 2 provides the highest strength among conventional Zamak alloys.
Corrosion Resistance
| Environment | Performance |
|---|---|
| Indoor Environment | Excellent |
| Dry Atmosphere | Excellent |
| Humid Environment | Good |
| Industrial Atmosphere | Good |
| Outdoor Exposure | Moderate |
| Salt Spray Environment | Fair |
Protective finishes are recommended for long-term outdoor applications.
Recommended surface treatments:
- Electroplating
- Chrome Plating
- Nickel Plating
- Powder Coating
- Painting
- Passivation
Wear Resistance
| Property | Performance |
|---|---|
| Abrasion Resistance | Excellent |
| Bearing Performance | Excellent |
| Sliding Wear Resistance | Excellent |
| Surface Durability | Excellent |
The high copper content gives Zamak 2 superior wear performance compared with other Zamak grades.
Castability
| Property | Rating |
|---|---|
| Die Fill Capability | Excellent |
| Dimensional Accuracy | Excellent |
| Thin Wall Casting | Excellent |
| Surface Finish Quality | Excellent |
Zamak 2 is ideal for complex die-cast components with tight tolerances.
Machinability
| Process | Rating |
|---|---|
| CNC Turning | Excellent |
| CNC Milling | Excellent |
| Drilling | Excellent |
| Tapping | Excellent |
| Grinding | Good |
Machinability Comparison
| Material | Machinability |
|---|---|
| Brass C360 | Excellent |
| Zamak 2 | Excellent |
| Aluminum 6061 | Excellent |
| Stainless Steel 304 | Moderate |
Secondary machining is often minimal due to excellent casting precision.
Heat Treatment
Heat Treatment Characteristics
| Property | Performance |
|---|---|
| Heat Treat Hardening | Not Recommended |
| Structural Stability | Excellent |
| Aging Resistance | Good |
| Creep Resistance | Excellent |
Zamak 2 obtains its properties primarily through alloy composition rather than heat treatment.
International Equivalent Grades
| Standard | Equivalent Grade |
|---|---|
| ASTM (USA) | Zamak 2 |
| UNS | Z35530 |
| DIN (Germany) | ZnAl4Cu3 |
| EN (Europe) | ZL0430 |
| ISO | Zamak 2 |
| JIS (Japan) | Zinc Alloy No.2 |
| GB/T (China) | YX040 |
Available Forms
| Product Type | Availability |
|---|---|
| Die Cast Components | Yes |
| Ingots | Yes |
| Precision Cast Parts | Yes |
| Custom Castings | Yes |
Typical Applications
Automotive Industry
- Door Lock Components
- Handles
- Brackets
- Transmission Components
Industrial Machinery
- Gears
- Bearings
- Housings
- Mechanical Hardware
Security Industry
- Lock Bodies
- Key Components
- Hardware Systems
Electrical Industry
- Connectors
- Switch Housings
- Electrical Hardware
Consumer Products
- Appliance Components
- Decorative Hardware
- Furniture Hardware
Precision Engineering
- High-Load Die Cast Parts
- Structural Components
- Precision Assemblies
Manufacturing Characteristics
| Manufacturing Process | Rating |
|---|---|
| High Pressure Die Casting | Outstanding |
| CNC Machining | Excellent |
| Plating | Excellent |
| Polishing | Excellent |
| Surface Finishing | Excellent |
Advantages
Highest Strength Among Zamak Alloys
Superior mechanical properties compared with Zamak 3 and Zamak 5.
Excellent Wear Resistance
Ideal for gears, bearings, and moving mechanical components.
Outstanding Castability
Produces complex shapes with excellent dimensional accuracy.
Good Creep Resistance
Performs well under long-term mechanical loading.
Excellent Surface Finish
Suitable for decorative and functional applications.
Cost Effective
Offers high performance at a competitive manufacturing cost.
Limitations
Lower Ductility
Less elongation than Zamak 3.
Heavier Than Aluminum
Higher density limits lightweight applications.
Moderate Outdoor Corrosion Resistance
Protective coatings are recommended.
Not Suitable for High Temperatures
Mechanical properties decrease significantly above 100°C.
Comparison with Other Zamak Alloys
| Property | Zamak 2 | Zamak 3 | Zamak 5 |
|---|---|---|---|
| Strength | Highest | Moderate | High |
| Hardness | Highest | Moderate | High |
| Wear Resistance | Excellent | Good | Very Good |
| Ductility | Lower | Highest | Moderate |
| Castability | Excellent | Excellent | Excellent |
Comparison with Common Die Casting Materials
| Material | Density | Tensile Strength | Castability |
|---|---|---|---|
| Zamak 2 | 6.6 g/cm³ | 410 MPa | Excellent |
| Zamak 3 | 6.6 g/cm³ | 283 MPa | Excellent |
| Zamak 5 | 6.6 g/cm³ | 330 MPa | Excellent |
| Aluminum A380 | 2.73 g/cm³ | 325 MPa | Excellent |
Available Surface Finishes
Raw Finishes
- As-Cast Finish
- Shot Blasted Finish
Functional Finishes
- Precision Machined Finish
- Polished Finish
- Brushed Finish
Decorative Finishes
- Chrome Plating
- Nickel Plating
- Black Coating
- Powder Coating
- Painted Finish
Frequently Asked Questions (FAQ)
What is Zamak 2?
Zamak 2 is a high-strength zinc die-casting alloy containing aluminum, copper, and magnesium.
What is Zamak 2 used for?
Typical applications include:
- Gears
- Bearings
- Lock Components
- Automotive Hardware
- Precision Die Cast Parts
What is the equivalent material to Zamak 2?
Common equivalents include:
- UNS Z35530
- ZnAl4Cu3
- ZL0430
- YX040
What is the difference between Zamak 2 and Zamak 3?
| Property | Zamak 2 | Zamak 3 |
|---|---|---|
| Strength | Higher | Lower |
| Hardness | Higher | Lower |
| Wear Resistance | Better | Good |
| Ductility | Lower | Better |
Is Zamak 2 corrosion resistant?
Yes. It offers good corrosion resistance, especially when protected with plating or coatings.
Can Zamak 2 be machined?
Yes. Zamak 2 offers excellent machinability and is commonly machined after casting.
Why choose Zamak 2?
Because it combines:
- High Strength
- Excellent Wear Resistance
- Outstanding Castability
- Good Creep Resistance
- Excellent Surface Finish Quality
Is Zamak 2 suitable for gears and bearings?
Yes. Its high hardness and wear resistance make it ideal for these applications.
Does GCNOV provide custom manufacturing services for Zamak 2?
Yes. GCNOV provides:
- Zinc Die Casting
- Precision CNC Machining
- Surface Finishing
- Electroplating
- Prototype Development
- Low-Volume Production
- Mass Production
- Custom Mechanical Components