Zinc alloys are the easiest for die casting. Leading the way is ZAMAK. What is ZAMAK? It is a type of zinc alloy that consists of aluminum, magnesium, copper, and of course zinc. Despite the copper content, this zinc alloy family spells its name with a K. Interestingly, despite including copper, the name ZAMAK uses a ‘K’ instead of a ‘C.’ That’s because the acronym comes from the German spellings of the elements: Zink, Aluminum, Magnesium, and Kupfer (the German word for copper).
That being said, you may see it spelled ZAMAC with an English spelling instead of the common ZAMAK spelling. ZAMAK alloys are a separate family from the zinc aluminum (ZA) alloys. Although they both maintain a consistent composition of 4% aluminum.
Precision zinc alloys are a crucial component in the manufacturing process that has transformed metal casting.
In the 1920s, developers first introduced ZAMAK for high-pressure die casting. This development is a groundbreaking innovation that influenced the zinc die casting industry.
In the early 20th century, began the evolution of the zinc alloys known today. During this period, manufacturers in the automotive and toy industries compiled various low-cost metals with lower melting temperatures. They subsequently melted down these “pot metals” and cast them as a mixture into distinct parts.
Unlike today’s zinc metal alloys, this pot metal led to all sorts of problems. Highly precise zinc alloys emerged out of the complexity of pot metal, with ZAMAK leading the charge. After its development in 1929, precision zinc alloys took over the zinc die casting industry. To this day, ZAMAK remains the most extensively utilized alloy in the industry.
At Deco Products, the most common of the zinc alloys are in order of #3, #2, #5, and #7. Typically, #3 is the first choice with our customers when considering alloys for a zinc die casting project.
The most popular of the alloys with over 70% of all zinc die casting in alloy #3. The reason is its excellent balance of physical and mechanical properties.
Product engineers and designers will compare all die cast zinc alloys for a new product design. ZAMAK and ZA alloy families have similar compositions and are better in different application. Understand the end use of the part is essential to selecting the correct alloy.
Typically, ZAMAK alloys use a hot chamber die cast setting. ZA use a cold chamber die casting process similar to aluminum, therefore requires special melting procedures.
Several reasons product engineers and designers choose zinc alloys for casting parts. Their low melting point makes them easy to work with, while resistance to corrosion making them suitable for outdoor use. Additionally, zinc is a versatile material for a wide range of products.
A: Zinc fluidity allows for casting to tight tolerances and dimensional accuracy. The casting to final shape or “Net Shape” manufacturing to reduce or eliminate costly machining.
A: ZAMAK allow for several finishes such as paint, plated, or powder coating providing an appealing look and texture.
A: Zinc alloys are stronger per unit weight than many other common materials, offering a favorable strength-to-weight ratio. This makes zinc die cast parts ideal for applications where both strength and weight are critical considerations. Specifically, zinc alloys provide higher tensile strength compared to most plastics and lower-density metals while maintaining excellent dimensional stability and thin-wall capability, which further contributes to their efficiency in structural applications.
A: A reason to select zinc is longer tool life. A typical zinc mold can last up to a million shots. In parts with a high-volume, zinc offers a cost-effective solution.
ZAMAK, a zinc alloy for die casting changed high-pressure die casting in the 1920s.
The different zinc alloys have the ability to cast high quality parts with high strengths and finishes. Zinc’s superior strength-to-weight ratio, casting to thin wall parts and dimensional stability, make it a preferred choice.
View our zinc alloys page to learn more about zinc alloy use at Deco Products.
Deco Products is a full-service zinc die-caster that offers precision zinc die-castings to customers globally. We utilize custom-designed hot-chambered die-casting machines to offer you competitive and quality products.
