Engineer Perspective on Zinc Alloy Die Caster

Zinc alloys have long been celebrated for their diverse range of strengths and properties, making them a popular choice for various industrial applications. With a plethora of alloys available, each with its own unique characteristics, it’s important to understand the specific strengths and applications of each alloy to make informed decisions for component manufacturing.

Exploring the Strengths of Zinc Alloys

Alloy number three stands out as one of the most widely used zinc alloys, prized for its exceptional fluidity properties and impressive impact resistance. Its superior finishing capabilities make it a top choice for many applications, offering a perfect blend of strength and versatility.

Meanwhile, alloy number five boasts remarkable strength capabilities, making it a valuable contender in the zinc alloy die caster market. As a cost-effective option, its widespread usage reduces expenses for component production, making it an attractive choice for manufacturers.

In the realm of zinc-aluminum alloys, zinc-aluminum hot chamber eight takes the spotlight for its remarkable tensile strength. While it may not excel in compressive strength, it remains a formidable choice for applications that prioritize tensile strength.

Alloy number two emerges as a superior choice for intensive as well as compressive strength, offering a well-rounded solution for diverse applications.

Lastly, the innovative EZAC alloy, with its impressive strength and bending resistance, presents a promising addition to the market, providing a glimpse into the future of zinc alloy applications.

In conclusion, the world of zinc alloys is a rich tapestry of diverse strengths and capabilities, each alloy offering distinct advantages for specific applications. Understanding the unique properties of each alloy is crucial for making informed decisions in component manufacturing. With the constant evolution of alloys like EZAC, the future holds exciting possibilities for further advancements in the strength and versatility of zinc alloys.

Listen to Jim Meyers, our senior engineer, compare the different alloys of zinc like Zamak 3, Zamak 5, ZA – 8, Zamak 2, and EZAC by watching the video below.

Zinc Alloy | Die Caster Perspective

Zamak No. 3

The most widely used zinc alloy is commonly called No. 3. Its excellent all-around physical and mechanical properties, superb cast-ability, and long-term dimensional stability have made it the choice for about 85% of U.S. die-castings. In most design applications using a zinc alloy, No. 3 will do the job.  In general, only after casting design improvements have been evaluated and found inadequate should another alloy be considered.

Zamak No. 5

The addition of about l% copper to the No. 3 alloy provides increased tensile strength (about 15%) and higher hardness at the expense of elongation and impact strength. No. 5 alloy is widely used in Europe, but accounts for less than 10% of U.S. consumption.

Zamak No. 2

Actually, a predecessor of the universal No. 3 alloy, No. 2 offers the highest strength and hardness available in a conventional zinc alloy. It is about 25% stronger as cast than No. 3 and 10% stronger than No. 5 with higher hardness than both.

The principle disadvantages of this interesting alloy are its very low impact strength and elongation after aging (especially at higher temperatures) and a slight dimensional instability with aging.


Offers best plating and finishing characteristics with improved strength, hardness and creep properties compared to the other conventional zinc ZAMAK die casting alloys. Major application area is usually for die casting where improved properties over ZAMAK’s are required, particularly performance at elevated temperatures.


This is the most recent development in commercially available zinc die casting alloys. Research has shown EZACTM to be the most creep resistant of all the zinc die casting alloys with over an order of magnitude improvement over ZAMAK 5 and ZA-8. This is also a very strong alloy with a yield strength (57 ksi) and hardness (102-134 brinell) comparable to ZA-27.

Due to its low melting temperature, EZACTM can be cast in a hot chamber die casting machine and does not exhibit the same wear and tear as shown with ACuZinc®5.

Deco Products has been a “Made in USA” zinc alloy die caster since 1960.

Deco Products provides exceptional service and quality products for a multitude of industries. A few services Deco Products provides are custom precision engineered zinc die casting, powder coating, assembly, CNC Machining, and DFM-Part Design. Deco has been a stable and reliable supplier to the industry and continuously strives for being the best value for its key partner/customers.
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Michele Duwe

Michele Duwe is the Sales and Marketing Manager with Deco Products. She has seven plus years as a digital marketing manager and a decade of sales and marketing experience.

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