Overview
Zamak 5 is one of the most widely used zinc die-casting alloys, offering an excellent combination of strength, hardness, corrosion resistance, castability, and dimensional stability. It contains approximately 4% aluminum and 1% copper, providing higher strength and wear resistance than Zamak 3 while maintaining excellent casting characteristics.
Because of its superior mechanical properties and reliable manufacturing performance, Zamak 5 is extensively used in automotive, hardware, consumer products, electronics, and industrial applications.
Zamak 5 is widely used in:
- Automotive Components
- Door and Window Hardware
- Lock Systems
- Electrical Components
- Industrial Machinery Parts
- Consumer Products
- Decorative Hardware
- Precision Die Cast Components
Due to its excellent balance of strength and castability, Zamak 5 is often considered the preferred choice for structural zinc die-cast parts.
Material Specification
| Property | Value |
|---|---|
| Material Designation | Zamak 5 |
| 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 Components, Ingots |
Chemical Composition
| Element | Content (%) |
|---|---|
| Zinc (Zn) | Balance |
| Aluminum (Al) | 3.8–4.3 |
| Copper (Cu) | 0.75–1.25 |
| Magnesium (Mg) | 0.03–0.06 |
| Iron (Fe) | ≤0.075 |
| Lead (Pb) | ≤0.003 |
| Cadmium (Cd) | ≤0.003 |
| Tin (Sn) | ≤0.001 |
The copper addition improves tensile strength, hardness, creep resistance, and wear performance compared with Zamak 3.
Mechanical Properties
As-Cast Condition
| Property | Value |
|---|---|
| Tensile Strength | 310–340 MPa |
| Yield Strength | 250–280 MPa |
| Elongation | 7–10% |
| Hardness | 90–120 HB |
| Elastic Modulus | 86 GPa |
Typical Mechanical Performance
| Property | Value |
|---|---|
| Fatigue Resistance | Good |
| Wear Resistance | Very Good |
| Impact Strength | Good |
| Creep Resistance | Very Good |
Physical Properties
| Property | Value |
|---|---|
| Density | 6.6 g/cm³ |
| Melting Range | 380–390°C |
| Thermal Conductivity | 109 W/m·K |
| Electrical Conductivity | 26% IACS |
| Electrical Resistivity | 0.065 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 5 | 6.6 | 330 MPa |
| Zamak 3 | 6.6 | 283 MPa |
| Zamak 2 | 6.6 | 410 MPa |
| Aluminum A380 | 2.73 | 325 MPa |
Zamak 5 offers higher strength than Zamak 3 while maintaining excellent castability and processing characteristics.
Corrosion Resistance
| Environment | Performance |
|---|---|
| Indoor Environment | Excellent |
| Dry Atmosphere | Excellent |
| Humid Environment | Good |
| Industrial Atmosphere | Good |
| Outdoor Exposure | Moderate |
| Salt Spray Environment | Fair |
Protective coatings are recommended for outdoor applications and decorative products.
Recommended surface treatments:
- Chrome Plating
- Nickel Plating
- Zinc Plating
- Powder Coating
- Painting
- Passivation
Wear Resistance
| Property | Performance |
|---|---|
| Abrasion Resistance | Very Good |
| Sliding Wear Resistance | Very Good |
| Surface Durability | Very Good |
| Bearing Performance | Good |
Zamak 5 provides better wear resistance than Zamak 3 due to its copper content.
Castability
| Property | Rating |
|---|---|
| Die Fill Capability | Excellent |
| Thin Wall Casting | Excellent |
| Surface Finish Quality | Excellent |
| Complex Geometry Casting | Excellent |
Zamak 5 is highly suitable for precision die-cast parts with intricate geometries.
Machinability
| Process | Rating |
|---|---|
| CNC Turning | Excellent |
| CNC Milling | Excellent |
| Drilling | Excellent |
| Tapping | Excellent |
| Grinding | Good |
Machinability Comparison
| Material | Machinability |
|---|---|
| Brass C360 | Excellent |
| Zamak 5 | Excellent |
| Aluminum 6061 | Excellent |
| Stainless Steel 304 | Moderate |
Secondary machining is often minimal due to excellent casting accuracy.
Heat Treatment
Heat Treatment Characteristics
| Property | Performance |
|---|---|
| Heat Treat Hardening | Not Recommended |
| Structural Stability | Excellent |
| Aging Resistance | Good |
| Creep Resistance | Very Good |
Zamak 5 derives its properties primarily from alloy composition and casting quality.
International Equivalent Grades
| Standard | Equivalent Grade |
|---|---|
| ASTM (USA) | Zamak 5 |
| UNS | Z35530 |
| DIN (Germany) | ZnAl4Cu1 |
| EN (Europe) | ZL0410 |
| ISO | Zamak 5 |
| JIS (Japan) | Zinc Alloy No.5 |
| GB/T (China) | YX041 |
Available Forms
| Product Type | Availability |
|---|---|
| Die Cast Components | Yes |
| Ingots | Yes |
| Precision Cast Parts | Yes |
| Custom Castings | Yes |
Typical Applications
Automotive Industry
- Door Handles
- Lock Components
- Brackets
- Mechanical Hardware
Construction Industry
- Window Hardware
- Door Hardware
- Fastening Systems
- Structural Fittings
Security Industry
- Lock Bodies
- Security Components
- Key Systems
Electronics Industry
- Connector Housings
- Electrical Hardware
- Equipment Enclosures
Consumer Products
- Appliance Components
- Decorative Hardware
- Household Products
Industrial Manufacturing
- Precision Mechanical Components
- Machine Parts
- Structural Castings
Manufacturing Characteristics
| Manufacturing Process | Rating |
|---|---|
| High Pressure Die Casting | Outstanding |
| CNC Machining | Excellent |
| Electroplating | Excellent |
| Polishing | Excellent |
| Surface Finishing | Excellent |
Advantages
Higher Strength Than Zamak 3
Improved load-bearing capability for structural components.
Excellent Castability
Produces highly detailed and accurate die-cast parts.
Good Wear Resistance
Suitable for moving mechanical assemblies.
Excellent Surface Finish
Ideal for plated and decorative applications.
Good Corrosion Resistance
Performs well in indoor and commercial environments.
Cost Effective
Provides excellent performance for high-volume manufacturing.
Limitations
Lower Ductility Than Zamak 3
Less suitable for applications requiring significant deformation.
Higher Density Than Aluminum
Not ideal for lightweight designs.
Moderate Outdoor Corrosion Resistance
Protective coatings are recommended.
Limited High-Temperature Performance
Not recommended for continuous service above 100°C.
Comparison with Other Zamak Alloys
| Property | Zamak 5 | Zamak 3 | Zamak 2 |
|---|---|---|---|
| Strength | High | Moderate | Highest |
| Hardness | High | Moderate | Highest |
| Wear Resistance | Very Good | Good | Excellent |
| Ductility | Moderate | Highest | Lower |
| Castability | Excellent | Outstanding | Excellent |
Comparison with Common Die Casting Materials
| Material | Density | Tensile Strength | Castability |
|---|---|---|---|
| Zamak 5 | 6.6 g/cm³ | 330 MPa | Excellent |
| Zamak 3 | 6.6 g/cm³ | 283 MPa | Outstanding |
| Aluminum A380 | 2.73 g/cm³ | 325 MPa | Excellent |
| Brass C360 | 8.5 g/cm³ | 345 MPa | Poor |
Available Surface Finishes
Raw Finishes
- As-Cast Finish
- Shot Blasted Finish
Functional Finishes
- Precision Machined Finish
- Brushed Finish
- Polished Finish
Decorative Finishes
- Chrome Plating
- Nickel Plating
- Satin Chrome Finish
- Powder Coating
- Painted Finish
Frequently Asked Questions (FAQ)
What is Zamak 5?
Zamak 5 is a zinc-aluminum-copper die-casting alloy designed for higher strength and wear resistance than Zamak 3.
What is Zamak 5 used for?
Typical applications include:
- Automotive Components
- Door Hardware
- Lock Systems
- Electrical Components
- Industrial Machinery Parts
What is the equivalent material to Zamak 5?
Common equivalents include:
- UNS Z35530
- ZnAl4Cu1
- ZL0410
- YX041
What is the difference between Zamak 3 and Zamak 5?
| Property | Zamak 3 | Zamak 5 |
|---|---|---|
| Strength | Lower | Higher |
| Wear Resistance | Good | Better |
| Ductility | Higher | Lower |
| Structural Applications | Moderate | Better |
Is Zamak 5 corrosion resistant?
Yes. Zamak 5 offers good corrosion resistance, especially when plated or coated.
Can Zamak 5 be machined?
Yes. Zamak 5 provides excellent machinability and is commonly machined after casting.
Why choose Zamak 5?
Because it combines:
- Higher Strength
- Excellent Castability
- Good Wear Resistance
- Excellent Surface Finish
- Cost-Effective Manufacturing
Is Zamak 5 suitable for structural die-cast components?
Yes. It is one of the most commonly used zinc alloys for load-bearing die-cast parts.
Does GCNOV provide custom manufacturing services for Zamak 5?
Yes. GCNOV provides:
- Zinc Die Casting
- Precision CNC Machining
- Electroplating
- Surface Finishing
- Prototype Development
- Low-Volume Production
- Mass Production
- Custom Structural Components