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Zamak 

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Zamak ingot

Zamak (formerly trademarked as ZAMAK [1]

 and also known as Zamac) is a family of  alloys 

with a base metal of  zinc and alloying elements of  aluminium, magnesium, and copper . Zamak 

alloys are part of the zinc aluminium alloy family; they are distinguished from the other ZAalloys because of their constant 4% aluminium composition.

[2] The name  zamak is an acronym of 

the German names for the metals of which the alloys are composed:  Zink (zinc), Aluminium,

 Magnesium and  Kupfer (copper).[2]

 The  New Jersey Zinc Company developed zamak alloys in1929. While zinc alloys are popularly referred to as  pot metal or  white metal, zamak is held to

higher industrial standards.

The most common zamak alloy is zamak 3, but zamak 2, zamak 5 and zamak 7 are stillcommercially used.[2]

 These alloys are most commonly die cast.[2]

 Zamak alloys (particularly #3

and #5) are frequently used in the spin casting industry.

A large problem with early zinc die casting materials was zinc pest, owing to impurities in the

alloys.[3]

 Zamak avoided this by the use of 99.99% pure zinc metal, produced by  New JerseyZinc's use of a refluxer  as part of the smelting  process.

Zamak can be electroplated, wet painted, and chromate conversion coated well.[4]

 

Contents

  1 Mazak  

  2 Standards 

  3 Zamak 2 

o  3.1 KS 

  4 Zamak 3 

  5 Zamak 4 

  6 Zamak 5 

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  7 Zamak 7 

  8 Uses 

  9 References 

  10 External links 

Mazak 

In the early 1930s Morris Ashby in Britain had licensed the New Jersey zamak alloy. The high-

 purity refluxer zinc was not available in Britain and so they acquired the right to manufacture the

alloy using a locally available electrolytically refined zinc of 99.95% purity. This was given thename Mazak , partly to distinguish it from zamak and partly from the initials of Morris Ashby. In

1933,  National Smelting licensed the refluxer patent with the intent of using it to produce

99.99% zinc in their plant at Avonmouth.[5]

 

Standards

Zinc alloy chemical composition standards are defined per country by the standard listed below:

Zinc alloy standards per country  

Country Zinc ingot Zinc casting

Europe EN1774 EN12844

USA ASTM B240 ASTM B86

Japan JIS H2201 JIS H5301

Australia AS 1881 - SAA H63 AS 1881 - SAA H64

China GB 8738-88 -

Canada CSA HZ3 CSA HZ11

International ISO 301 -

Zamak goes by many different names based on standard and/or country:

Various names for zamak alloys

Traditio

nal

name

Short

composit

ion name

For

m

Comm

on

AST

M† 

Short

Europe

an

designat

ion

JISChin

a

UK 

BS

1004[7]

 

Franc

e

NFA

55-

010[7] 

Germ

any

DIN

1743-

2[7] 

UNSOth

er

Zamak 2

[8][9] 

or 

Kirksite[

10] 

ZnAl4Cu3

[11] 

Ingot

Alloy2

[8][9] 

AG

43A[8

][9] 

ZL0430[

11] 

-ZX04[12]

 -

Z-

A4U3[11]

 

Z430[1

1] 

Z35540

[9] 

ZL2

,ZA-

2,

ZN-002

[

13] 

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Cas

tZP0430 -

Z3554

1[8]

 

ZP2,ZA-2,

ZN-

002[

13]

 

Zamak 

3[8][9]

 ZnAl4

[11] 

Ing

ot

Alloy

3[8][9]

 

AG

40A[8

][9] 

ZL0400[

11] 

Ingottype

2[14]

 

ZX01[12]

 

Allo

y

A[11]

 

Z-

A4[11]

 

Z400[1

1] 

Z3552

1[9]

 

ZL3

,

ZA-3,

ZN-

003[

13] 

Cas

t ZP0400

ZDC2

[15]  -

Z3352

0[8] 

ZP3,

ZA-

3,

ZN-003

[

13] 

Zamak 4

[16] 

Ingot

Used in Asia only

ZA-4,

ZN-

004[

13] 

Zamak 

5[8][9]

 

ZnAl4Cu

1[11]

 

Ingot

Alloy

5[8][9]

 

AG

41A[8

][9] 

ZL0410[

11] 

Ingot

type1

[14] 

ZX03[12] 

Allo

y

B[11]

 

Z-

A4UI[

11] 

Z410[1

1] 

Z35530

[9] 

ZL5

,

ZA-

5,ZN-

005[

13] 

Cas

tZP0410

ZDC1[15]

 -

Z3553

1[8]

 

ZP5,

ZA-

5,

ZN-005

[

13] 

Zamak 

7[8][9]

 

ZnAl4Ni[

12] 

Ingot

Alloy

7[8][9]

 

AG40B

[8

][9] 

- -

ZX02[12] 

- - -

Z33522

[9] 

ZA-7,ZN-

007[

13] 

Cas

t-

Z3352

3[8]

 

color of the cell is the color of the material designated by ASTM B908.

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The Short European Designation code breaks down as follows (using ZL0430 as the

example):[11]

 

  Z is the material (Z=Zinc)

  P is the use (P=Pressure die casting (casting), L=Ingot)

 04 is the percent aluminium (04= 4% aluminium)

  3 is the percent copper (3= 3% copper)

Zamak 2

Zamak 2 has the same composition as zamak 3 with the addition of 3% copper in order to

increase strength by 20%, which also increases the price. Zamak 2 has the greatest strength out

of all the zamak alloys. Over time it retains its strength and hardness better than the other alloys;however, it becomes more brittle, shrinks, and less elastic.

[17] 

Zamak 2 is also known as  Kirksite when gravity cast for use as a die.[2][18]

 It was originally

designed for low volume sheet metal dies.[19] It later gained popularity for making short runinjection molding dies.

[19] It is also less commonly used for non-sparking tools and mandrels for 

metal spinning.

Zamak 2 composition per standard

Alloying elements Impurities

Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl

ASTM B240[20]

 (Ingot)min 3.9 2.6 0.025 - - - - - - - -

max 4.3 2.9 0.05 0.004 0.003 0.002 0.075 - - - -

ASTM B86[21]

 (Cast)

min 3.5 2.6 0.025 - - - - - - - -

max 4.3 2.9 0.05 0.005 0.004 0.003 0.1 - - - -

EN1774[22]

 (Ingot)min 3.8 2.7 0.035 - - - - - - - -

max 4.2 3.3 0.06 0.003 0.003 0.001 0.02 0.001 0.02 - -

EN12844[23]

 (Cast)min 3.7 2.7 0.025 - - - - - - - -

max 4.3 3.3 0.06 0.005 0.005 0.002 0.05 0.02 0.03 - -

GB8738-88[12]

 min 3.9 2.6 0.03 - - - - - - - -

max 4.3 3.1 0.06 0.004 0.003 0.0015 0.035 - - - -

Zamak 2 properties

Property Metric value English value

Mechanical properties

Ultimate tensile strength397 MPa (331 MPaaged)

58,000 psi

Yield strength (0.2% offset) 361 MPa 52,000 psi

Impact strength 38 J (7 J aged)28 ft-lbf (5 ft-lbf 

aged)

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Elongation at Fmax 3% (2% aged)

Elongation at fracture 6%

Shear strength 317 MPa 46,000 psi

Compressive yield strength 641 MPa 93,000 psi

Fatigue strength (reverse bending 5x10cycles) 59 MPa 8,600 psi

Hardness 130 Brinell (98 Brinell aged)

Modulus of elasticity 96 GPa 14,000,000 psi

Physical properties

Solidification range (melting range) 379 — 390 °C 714 — 734 °F

Density 6.8 kg/dm 0.25 lb/in

Coefficient of thermal expansion 27.8 μm/m-°C 15.4 μin/in-°F

Thermal conductivity 105 W/m-K 729 BTU-in/hr-ft -°F

Electrical resistivity 6.85 μΩ-cm at 20 °C 2.70 μΩ-in at 68 °F

Latent heat (heat of fusion) 110 J/g 4.7x10− BTU/lb

Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F

Coefficient of friction 0.08

KS

The KS alloy was developed for spin casting decorative parts. It has the same composition as

zamak 2, except with more magnesium in order to produce finer grains and reduce the orange

 peel effect.[24]

 

KS composition  

Alloying elements Impurities

Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl

 Nyrstar min 3.8 2.5 0.4 - - - - - - - -

max 4.2 3.5 0.6 0.003 0.003 0.001 0.020 - - - -

KS properties

Property Metric value English value

Mechanical properties

Ultimate tensile strength < 200 MPa < 29,000 psi

Yield strength (0.2% offset) < 200 MPa < 29,000 psi

Elongation < 2%

Hardness 150 Brinell max

Physical properties

Solidification range (melting range) 380 — 390 °C 716 — 734 °F

Density 6.6 g/cm 0.25 lb/in

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Coefficient of thermal expansion 28.0 μm/m-°C 15.4 μin/in-°F

Thermal conductivity 105 W/m-K 729 BTU-in/hr-ft -°F

Electrical conductivity 25% IACS

Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F

Coefficient of friction 0.08

Zamak 3

Zamak 3 is the de facto standard for the zamak series of zinc alloys; all other zinc alloys arecompared to this. Zamak 3 has the base composition for the zamak alloys (96% zinc, 4%

aluminium). It has excellent castability and long term dimensional stability. More than 70% of 

all North American zinc die castings are made from zamak 3.[2]

 

Zamak 3 composition per standard

Alloyingelements Impurities

Standard Limit Al Cu†

Mg Pb Cd Sn Fe Ni Si In Tl

ASTM B240[20]

 (Ingot)

min 3.9 - 0.025 - - - - - - - -

max 4.3 0.1 0.05 0.004 0.003 0.002 0.075 - - - -

ASTM B86[21]

 

(Cast)

min 3.5 - 0.025 - - - - - - - -

max 4.3 0.25 0.05 0.005 0.004 0.003 0.1 - - - -

EN1774[22]

 (Ingot)min 3.8 - 0.035 - - - - - - - -

max 4.2 0.03 0.06 0.003 0.003 0.001 0.02 0.001 0.02 - -

EN12844[23]

 (Cast)

min 3.7 - 0.025 - - - - - - - -

max 4.3 0.1 0.06 0.005 0.005 0.002 0.05 0.02 0.03 - -

JIS H2201[14]

 

(Ingot)

min 3.9 - 0.03 - - - - - - - -

max 4.3 0.03 0.06 0.003 0.002 0.001 0.075 - - - -

JIS H5301[15]

 

(Cast)

min 3.5 - 0.02 - - - - - - - -

max 4.3 0.25 0.06 0.005 0.004 0.003 0.01 - - - -

AS1881[25]

 min 3.9 - 0.04 - - - - - - - -

max 4.3 0.03 0.06 0.003 0.003 0.001 0.05 - 0.001 0.0005 0.001

GB8738-88[12]

 min 3.9 - 0.03 - - - - - - - -

max 4.3 0.1 0.06 0.004 0.003 0.0015 0.035 - - - -

Impurity

Zamak 3 properties

Property Metric value English value

Mechanical properties

Ultimate tensile strength 268 MPa 38,900 psi

Yield strength (0.2% offset) 208 MPa 30,200 psi

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Impact strength 46 J (56 J aged) 34 ft-lbf (41 ft-lbf aged)

Elongation at Fmax 3%

Elongation at fracture 6.3% (16% aged)

Shear strength 214 MPa 31,000 psi

Compressive yield strength 414 MPa 60,000 psiFatigue strength (reverse bending 5x10 cycles) 48 MPa 7,000 psi

Hardness 97 Brinell

Modulus of elasticity 96 GPa 14,000,000 psi

Physical properties

Solidification range (melting range) 381 — 387 °C 718 — 729 °F

Density 6.7 g/cm 0.24 lb/in

Coefficient of thermal expansion 27.4 μm/m-°C 15.2 μin/in-°F

Thermal conductivity 113 W/mK 784 BTU-in/hr-ft -°F

Electrical resistivity 6.37 μΩ-cm at 20 °C 2.51 μΩ-in at 68 °F

Latent heat (heat of fusion) 110 J/g 4.7x10−

BTU/lb

Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F

Coefficient of friction 0.07

Zamak 4

Zamak 4 was developed for the Asian markets to reduce the effects of  die soldering whilemaintaining the ductility of zamak 3. This was achieved by using half the amount of copper from

the zamak 5 composition.[26]

 

Zamak 4 composition per standard

Alloying

elementsImpurities

Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl

 Ningbo Jinyi Alloy

Material Co.[13]

 

min 3.9 0.3 0.03 - - - - - - - -

max 4.3 0.5 0.06 0.003 0.002 0.002 0.075 - - - -

Genesis Alloys Ltd.[27]

 min 3.9 0.3 0.04 - - - - - - - -

max 4.2 0.4 0.05 0.003 0.002 0.001 0.02 0.001 0.02 0.0005 0.001

Zamak 4 properties

Property Metric value English value

Mechanical properties

Ultimate tensile strength 317 MPa 46,000 psi

Yield strength (0.2% offset) 221 — 269 MPa 32,000 — 39,000 psi

Impact strength 61 J (7 J aged) 45 ft-lbf (5 ft-lbf aged)

Elongation 7%

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Shear strength 214 — 262 MPa 31,000 — 38,000 psi

Compressive yield strength 414 — 600 MPa 60,000 — 87,000 psi

Fatigue strength (rotary bending5x10

8cycles)

48 — 57 MPa 7,000 — 8,300 psi

Hardness 91 Brinell

Physical properties

Solidification range (melting range) 380 — 386 °C 716 — 727 °F

Density 6.6 g/cm 0.24 lb/in

Coefficient of thermal expansion 27.4 μm/m-°C 15.2 μin/in-°F

Thermal conductivity108.9 — 113.0 W/m-K @

100 °C

755.6 — 784.0 BTU-in/hr-ft -°F

@ 212 °F

Electrical conductivity 26-27% IACS

Specific heat capacity 418.7 J/kg-°C 0.100 BTU/lb-°F

Zamak 5

Zamak 5 has the same composition as zamak 3 with the addition of 1% copper in order to

increase strength (by approximately 10%[17]

), hardness and corrosive resistance, but reduces

ductility.[30]

 It also has less dimensional accuracy.[30]

 Zamak 5 is more commonly used inEurope.

[2] 

Zamak 5 composition per standard

Alloying

elementsImpurities

Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl Zn

ASTM B240[20]

 

(Ingot)

min 3.9 0.75 0.03 - - - - - - - -

max 4.3 1.25 0.06 0.004 0.003 0.002 0.075 - - - -

ASTM B86[21]

 (Cast)

min 3.5 0.75 0.03 - - - - - - - -

max 4.3 1.25 0.06 0.005 0.004 0.003 0.1 - - - -

EN1774[22]

 

(Ingot)

min 3.8 0.7 0.035 - - - - - - - -

max 4.2 1.1 0.06 0.003 0.003 0.001 0.02 0.001 0.02 - -

EN12844[23]

 

(Cast)

min 3.7 0.7 0.025 - - - - - - - -

max 4.3 1.2 0.06 0.005 0.005 0.002 0.05 0.02 0.03 - -

JIS H2201[14] (Ingot)

min 3.9 0.75 0.03 - - - - - - - -max 4.3 1.25 0.06 0.003 0.002 0.001 0.075 - - - -

JIS H5301[15]

 

(Cast)

min 3.5 0.75 0.02 - - - - - - - -

max 4.3 1.25 0.06 0.005 0.004 0.003 0.01 - - - -

AS1881[25]

 min 3.9 0.75 0.04 - - - - - - - -

max 4.3 1.25 0.06 0.003 0.003 0.001 0.05 - 0.001 0.0005 0.001

GB8738-88   min 3.9 0.7 0.03 - - - - - - - -

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max 4.3 1.1 0.06 0.004 0.003 0.0015 0.035 - - - -

Zamak 5 properties

Property Metric value English value

Mechanical properties

Ultimate tensile strength 331 MPa (270 MPaaged)

48,000 psi (39,000 psiaged)

Yield strength (0.2% offset) 295 MPa 43,000 psi

Impact strength 52 J (56 J aged) 38 ft-lbf (41 ft-lbf aged)

Elongation at Fmax 2%

Elongation at fracture 3.6% (13% aged)

Shear strength 262 MPa 38,000 psi

Compressive yield strength 600 MPa 87,000 psi

Fatigue strength (reverse bending 5x10

cycles)57 MPa 8,300 psi

Hardness 114 Brinell

Modulus of elasticity 96 GPa 14,000,000 psi

Physical properties

Solidification range (melting range) 380 — 386 °C 716 — 727 °F

Density 6.7 kg/dm 0.24 lb/in

Coefficient of thermal expansion 27.4 μm/m-°C 15.2 μin/in-°F

Thermal conductivity 109 W/mK 756 BTU-in/hr-ft -°F

Electrical resistivity 6.54 μΩ-cm at 20 °C 2.57 μΩ-in at 68 °F

Latent heat (heat of fusion) 110 J/g 4.7x10−

BTU/lb

Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F

Coefficient of friction 0.08

Zamak 7

Zamak 7 has less magnesium than zamak 3 to increase fluidity and ductility, which is especiallyuseful when casting thin wall components. In order to reduce inter-granular corrosion a small

amount of nickel is added and impurities are more strictly controlled.[2]

 

Zamak 7 composition per standard

Alloying elements Impurities

Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl

ASTM B240[20]

 (Ingot)min 3.9 - 0.01 - - - - - - - -

max 4.3 0.1 0.02 0.002 0.002 0.001 0.075 - - - -

ASTM B86[21]

 (Cast)min 3.5 - 0.005 - - - - 0.005 - - -

max 4.3 0.25 0.02 0.003 0.002 0.001 0.075 0.02 - - -

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GB8738-88[12]

 min 3.9 - 0.01 - - - - 0.005 - - -

max 4.3 0.1 0.02 0.002 0.002 0.001 0.075 0.02 - - -

Impurity Alloying element

Zamak 7 properties  

Property Metric value English valueMechanical properties

Ultimate tensile strength 285 MPa 41,300 psi

Yield strength (0.2% offset) 285 MPa 41,300 psi

Impact strength 58.0 J 42.8 ft-lbf 

Elongation at fracture 14%

Shear strength 214 MPa 31,000 psi

Compressive yield strength 414 MPa 60,000 psi

Fatigue strength (reverse bending 5x10 cycles) 47.0 MPa 6,820 psi

Hardness 80 BrinellPhysical properties

Solidification range (melting range) 381 — 387 °C 718 — 729 °F

Coefficient of thermal expansion 27.4 μm/m-°C 15.2 μin/in-°F

Thermal conductivity 113 W/m-K 784 BTU-in/hr-ft -°F

Electrical resistivity 6.4 μΩ-cm 2.5 μΩ-in

Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F

Casting temperature 395 — 425 °C 743 — 797 °F