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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