Zinc alloys offer excellent die casting capability for metal components with complex shapes, precise dimensions, and surface finishing requirements. Selecting the right alloy involves more than strength and hardness: ductility, long-term dimensional stability, operating temperature, and secondary operations also matter.
Zinc alloys are commonly used in locks, architectural and furniture hardware, industrial mechanisms, automotive components, and electronic products. The examples below provide starting points for material selection. The final choice should reflect the component design and operating conditions.
| Application | Component Examples | Key Selection Factors |
|---|---|---|
| Locks and architectural hardware | Lock bodies, handles, hinges, and fasteners | Strength, appearance, and durability |
| Industrial and mechanical components | Connecting parts, operating mechanisms, and transmission components | Load capacity, wear, and long-term deformation |
| Automotive components | Interior hardware, mounting parts, and mechanical components | Operating temperature, vibration, and dimensional accuracy |
| Electronics and telecommunications | Housings, connector shells, and shielding components | Precision casting, assembly, and electromagnetic shielding |
| Furniture and consumer products | Decorative hardware, knobs, and fittings | Surface finishing, appearance, and production consistency |
Zamak 3 combines good castability, ductility, and long-term dimensional stability. It is also well suited to electroplating and painting. It is a practical starting point for general precision components, cosmetic parts, and products requiring secondary riveting or crimping.
Zamak 5 contains approximately 1% copper. It generally offers greater strength and hardness than Zamak 3 while retaining good die casting and finishing characteristics. It is a suitable candidate for locks, hardware, and mechanical components that carry loads. Its lower ductility should be considered when bending, riveting, or crimping is required.
With approximately 3% copper, Zamak 2 offers higher strength, hardness, and creep resistance among the three Zamak alloys discussed here. It is a candidate for mechanical components subject to higher loads or where wear resistance is a priority. For parts with precision fits, dimensional changes caused by long-term ageing require particular attention.
ZA-8 contains approximately 8% aluminum and can be processed by hot chamber die casting. Its strength and creep resistance make it an additional option for mechanical components that carry loads. Ductility, casting conditions, and secondary operations should also be evaluated.
| Primary Requirement | Alloy to Consider First |
|---|---|
| General precision parts, cosmetic components, and dimensional stability | Zamak 3 |
| Greater strength and hardness with conventional volume production | Zamak 5 |
| Higher strength and hardness among Zamak 2, 3, and 5 | Zamak 2 |
| Additional load capacity and creep resistance | ZA-8 |
These recommendations are starting points, rather than exclusive applications for each alloy. Several zinc alloys may be suitable for the same component. The final selection depends on load, wall thickness, tolerances, temperature, and manufacturing process.
Zamak 7 may be considered when fluidity and fine detail reproduction are priorities. ZA-12 and ZA-27 have higher aluminum contents and use the cold chamber process when die cast. These alloys should not be treated as direct substitutes for conventional Zamak alloys without reviewing process and performance requirements.
The following typical values are taken from the International Zinc Association (IZA) engineering database. They support material comparison and preliminary design; they are not guaranteed properties of finished components.
| Property | Unit | Zamak 3 | Zamak 5 | Zamak 2 | ZA-8 |
|---|---|---|---|---|---|
| Ultimate tensile strength | MPa | 315 | 331 | 397 | 386.8 |
| Yield strength, 0.2% offset | MPa | 276 | 295 | 360 | 318.6 |
| Elongation at rupture | % | 7.73 | 3.43 | 5.99 | 3.41 |
| Young’s modulus | GPa | 84.3 | 84.5 | 84.4 | 82.7 |
| Poisson’s ratio | — | 0.27 | 0.27 | 0.27 | 0.29 |
| Shear strength | MPa | 214 | 262 | 317 | 275 |
| Brinell hardness | HB | 97 | 114 | 130 | 95–110 |
| Rotary bending fatigue strength, 5 × 10⁸ cycles | MPa | 48 | 57 | 59 | 103 |
| Unnotched Charpy impact strength, 20°C | J/cm² | 116 | 131 | 96 | Not listed |
Test Conditions and Use of Data
The values refer to die cast materials tested at 20°C. The tensile strength, yield strength, elongation, Young’s modulus, and hardness data correspond to specimens 1.5 mm thick, measured eight weeks after casting. The tensile test speed was 10 mm/min, with a 70 mm gauge length for elongation measurement.
Shear, fatigue, and impact data use different test conditions and should not be assumed to come from the same specimens or test series as the tensile data. Impact values are expressed in J/cm² and cannot be directly compared with absorbed energy values expressed in J.
Wall thickness, porosity, cooling conditions, ageing, and operating temperature can affect performance. This table may be used for preliminary CAE/FEA comparisons. Final design should use data representative of the actual material condition, together with appropriate safety factors.
How to interpret the data: Higher strength does not necessarily mean greater stiffness or impact toughness. Zamak 2, 3, and 5 have similar Young’s moduli. Creep resistance must be assessed against load, temperature, and time, rather than room-temperature tensile strength alone.
The table below consistently uses the EN 12844 casting compositions listed by IZA. All values are percentages by weight (wt.%). Alloy ingot and casting specifications differ and should not be used interchangeably for incoming material inspection.
| Element | Zamak 3 | Zamak 5 | Zamak 2 | ZA-8 |
|---|---|---|---|---|
| Aluminum (Al) | 3.7–4.3 | 3.7–4.3 | 3.7–4.3 | 8.0–8.8 |
| Copper (Cu) | ≤ 0.10 | 0.7–1.2 | 2.7–3.3 | 0.8–1.3 |
| Magnesium (Mg) | 0.025–0.050 | 0.025–0.050 | 0.025–0.050 | 0.015–0.030 |
| Zinc (Zn) | Balance | Balance | Balance | Balance |
This table lists the principal elements only and is not a complete acceptance specification. Impurities such as lead, cadmium, tin, and iron must also be controlled. Purchasing and inspection should follow the specified standard edition, complete composition requirements, and the supplier’s material certificate.
| Alloy | European Casting Designation | European Alloy Feedstock Designation | Chemical Symbol | Common Japanese Counterpart |
|---|---|---|---|---|
| Zamak 3 | ZP3 / ZP0400 | ZL3 / ZL0400 | ZnAl4 | ZDC2 |
| Zamak 5 | ZP5 / ZP0410 | ZL5 / ZL0410 | ZnAl4Cu1 | ZDC1 |
| Zamak 2 | ZP2 / ZP0430 | ZL2 / ZL0430 | ZnAl4Cu3 | — |
| ZA-8 | ZP8 / ZP0810 | ZL8 / ZL0810 | ZnAl8Cu1 | — |
ZP designations refer to castings, while ZL designations refer to alloy feedstock. Common U.S. designations include AG40A (Zamak 3), AG41A (Zamak 5), AC43A (Zamak 2), and ZA8. Composition limits may differ slightly between standards. Drawings and purchasing documents should state the alloy, applicable standard, and edition, rather than the generic alloy name alone.
Provide the component drawing, operating temperature, loading conditions, dimensional tolerances, surface finish, and secondary operation requirements. For components subject to sustained loads, repeated impacts, or precision fit requirements, include creep, fatigue, and dimensional changes due to ageing in the assessment. Confirm suitability through prototypes and finished-component testing.
Eastern Alloys: Zamak 3, Zamak 5, Zamak 2, and Zinc Die Casting Alloys
Data checked: October 5, 2026. The composition and designation tables summarize engineering database information. For formal acceptance, consult the original standard specified in the contract.
