Zamak Die Casting

Zamak Die casting is produced by the die casting process, which is an excellent way to create complex metal parts. The die casting process primarily works with a limited range of metals. Some popular metals are zinc, copper, aluminum, and magnesium. Among these, zinc holds significant importance and is widely used in various applications. ZAMAK die-casting alloy is the most pervasive zinc alloy.

ZAMAK die-casting has different types: HPDC, LPDC, and gravity. Since ZAMAK has a low melting point, the HPDC method is mainly preferred, and we normally call this zamak die casting machine a hot chamber die casting machine; on the other hand, an aluminum die casting machine is a cold chamber die casting machine.

This article highlights what die-casting ZAMAK alloys are and their benefits. Furthermore, it delves into the process by which foundries create ZAMAK die-casting parts.

Buyers, agents, dealers, or importers can get valuable information from this article. If you are looking for a complete guide to understand ZAMAK die-casting, this is the one you should look for. Let’s get started.

Introducing Die Casting ZAMAK Alloy

ZAMAK stands for Zinc, Aluminum, Magnesium, and Copper (Kupfer). It is a German metal alloy name. Zinc is the base material, ranging from 94% to 96%.

ZAMAK alloys offer benefits that make these alloys suitable for die-casting. In short, they provide a low melting point, high fluidity, and a strength-to-weight ratio. They also offer additional benefits that you will learn about in the following sections.

ZAMAK alloys are widely used in die-casting foundries. Die-cast ZAMAK alloy parts are prevalent in many applications. These casting parts are crucial, from car parts to electronics and hardware. They are also 100% recyclable.

Moreover, they usually come with a wide range of surface finishes. Because they provide good adhesion quality, you can apply a variety of surface treatments to ZAMAK parts. Because of this, ZAMAK alloy parts can offer a premium look. Moreover, they are widely used in decorative applications.

Different Types Die Casting ZAMAK Alloys

Die Casting ZAMAK alloys have many types or grades. This diversity typically arises due to the need for different situations. For example, some situations require high strength, while others require good flexibility.

Die-cast ZAMAK 3 and ZAMAK 5 die castings are two popular zinc grades.  ZAMAK 3 die casting offers a perfect balance of strength and flexibility. On the other hand, ZAMAK 5 die casting gives more strength and hardness. Both alloys are widely used in various applications.

You can also find other ZAMAK alloys. The following table summarizes different ZAMAK alloys. The table highlights their composition, benefits, and use.

Table 1 Die Casting ZAMAK Alloy Composition Table

ZAMAK Alloy Grade	Zinc	Aluminium	Magnesium	Copper	Other
ZAMAK Grade 2	Équilibre	4%	0.035%	1%	–
Die Cast ZAMAK 3	Équilibre	3.5 to 4.3%	0.02 to 0.05%	0.25%	Fe <0.1%, Pb <0.005%, Cd <0.004% and Sn <0.003%
ZAMAK 5 Die Casting	Équilibre	3.5 to 4.3%	0.03 to 0.06%	0.75 to 1.25%	Fe 0.75%, Pb 0.004%, Cd 0.003% and Sn 0.002%
ZAMAK Grade 7	Équilibre	3.5 to 4.3%	0.005 to 0.02%	0.25%	Fe 0.075%, Pb 0.003%, Cd 0.002% and Sn 0.001%

 

Table 2 ZAMAK Die Casting Alloy Summerize Table

ZAMAK Alloy Grade	Features	Applications
ZAMAK Grade 2	Strongest and hardest ZAMAK alloy	Heavy-duty tools and machine parts
Die Cast ZAMAK 3	Average strength, flexibility, and castability	Car parts, hardware, and electrical housings
ZAMAK 5 Die Casting	Stronger and harder than ZAMAK 3, good creep resistance	Gears, levers, and small machine parts
ZAMAK Grade 7	Highest flexibility and fluidity	Electrical terminals and connectors

Why Use Die Casting ZAMAK Alloys?

There are many reasons why you should use ZAMAK alloys. Because of their benefits, ZAMAK alloys sometimes replace aluminum casting. This section mainly talks about the benefits of die-casting ZAMAK alloys.

Reason #1: High Fluidity

Fluidity refers to how easily molten metal flows into a die casting mold during casting. High fluidity allows the ZAMAC alloy to fill the die cavity with ease. Because of this feature, you can create even more complex designs. This feature allows the molten metal to reach every corner of the design, ensuring high fluidity. As a result, you can get better-surfaced, finished die-casting parts.

Reason #2: toughness and high rigidity

Die-casting ZAMAK alloys are tough and can resist deformation. Because of this, these alloys are durable and perform well in continuous operation. ZAMAK 2 and 5 offer high rigidity and toughness.

Reason #3: High Strength-To-Weight Ratio

Die-casting ZAMAK alloys are both robust and lightweight. Aluminum offers a stronger strength-to-weight ratio than ZAMAK. Note that aluminum’s tensile strength is 310 MPa, while ZAMAK’s is 280 MPa. However, ZAMAK die-casting parts are also widely used in various applications.

Reason #4: Low Melting Point

The melting point of die-casting ZAMAK alloys ranges from 380 to 420 degrees Celsius (except for ZAMAK 2). It means you can quickly melt and solidify.

There are some benefits of a low melting point:

1. It reduces the energy cost.
2. It makes the production faster.
3. It also simplifies the production.
4. It ensures fewer defects in casting metal parts.

Reason #5: Excellent Adhesion

Excellent adhesion means that ZAMAK die-casting alloys effectively bond with coatings. You can do a wide range of surface treatments. As a result, electronic plating can enhance the appearance of your final part significantly. You can give it a premium look as per your design. Moreover, it enhances the corrosion resistance of your metal parts.

Reason #6: Excellent Wearing and Bearing Properties

Die-casting ZAMAK alloys resist wear and effectively endure friction. ZAMAK parts typically maintain quality and functionality. They remain intact even under continuous stress.

This feature is critical in die-casting. It reduces replacement costs, which is crucial for moving parts like gears and levers.

Reason #7: 100% recyclable and environmentally friendly.

ZAMAK die-casting alloys are 100% recyclable. You can completely melt and reuse it. It won’t waste any material, and you can use all scrap.

This feature typically reduces raw material costs and ensures no environmental impact. Note that recycled ZAMAK alloys retain the same quality as new material.

Reason #8: Cost-Effective

ZAMAK die-casting alloys are cost-effective solutions. They usually cost less than aluminum. According to 2024 market trends, ZAMAK metals are slightly more expensive than aluminum. However, ZAMAK alloys are cheaper than other metals and their alloys.

What Are The Limitations Of Die Casting ZAMAK Alloy?

ZAMAK die-casting metals offer numerous benefits, but they also present certain challenges.

1. These alloys have a low melting point. When used at varying temperatures, their properties change dramatically. However, they become fragile when the temperature rises too high.
2. When ZAMAK alloys are mixed with tin or lead, they lose some of their flexibility and corrosion resistance.
3. Some ZAMAK alloys may not be suitable for lightweight applications.

What Is ZAMAK Die Casting?

Z

AMAK die casting is a popular metal casting method. This method forces molten zamak alloy into a die or mold cavity under high pressure. The die or mold is generally made of high-quality tool steel. For each type of shape, there are specific dies; to proceed with the zamak die casting process, you need to have a hot chamber die casting machine.

Typically, the hot chamber die casting machine divides the material into two halves: one stationary and the other movable. When these halves are closed, the method uses an injection chamber to inject the molten metal into them. Once the metal is solidified, operators take the casting parts out using ejector pins. Since you are using ZAMAK alloys, this process is known as ZAMAK die casting.

ZAMAK alloy is suitable for HPDC, LPDC, and gravity die-casting. Well, you are already familiar with its advantages and limitations.

The ZAMAK die casting process

ZAMAK die casting, or zinc die casting, is also a process similar to that of other alloy materials such as aluminum ormagnesium.  Foundries must ensure precise and efficient production to ensure high-quality outcomes.From designing to surface treatment, each step needs professional work.   Here is a step-by-step guide to the ZAMAK die-casting process.

Step #1: Design and Making of Die

ZAMAK die casting begins by designing the final part and mold or die. This step is of utmost importance as it largely determines the outcome.

First, engineers from the foundry create the 3D model of the final part to be cast. They simulate it on various CAD software. Most of the time, they develop prototypes for testing and change the design if necessary. After making a few rapid prototypes, they finalize the casting part.

Next, they design the mold or die for the process. Similarly, they create 3D models and develop a few prototypes. During this process, they take into account several crucial parameters:

1. The injection type plays a crucial role in die-casting ZAMAK alloys. Because they have a low melting point, the injection system must be hot enough to keep the metal liquid.
2. The number of cavities is another critical parameter here. Engineers arrange these cavities for the best results.
3. The parting system typically designs how the two halves of the die will look. Final part quality and finishing and trimming depend on the parting line.
4. The ejector system generally releases the part from the mold. Its design should be accurate so it doesn’t damage the final part.
5. Engineers also carefully arrange the cooling system for the whole process. An appropriate cooling system prevents many casting defects.
6. Choosing a suitable material for the mold is also crucial in this situation. High-quality tool steels are usually used for this job. Popular tool steels are H13, SKD61, 8407, and 8418.

Step #2: Preparing ZAMAK alloy

Once the mold is ready, engineers install it with the machine. Next, they prepare the ZAMAK alloy. Various techniques are used to refine the ZAMAK alloy. Some popular methods are thermal refining, chemical reaction, electrolytic refining, and zone refining.

The method melts the ZAMAK alloy in a furnace to give it a liquid form. A proper temperature is controlled in this case, ensuring the alloy melts evenly. Engineers usually remove the impurities during this step.

After refining, the process keeps the molten metal in the injection chamber. Once again, the temperature is controlled correctly here. Furthermore, it is essential to ensure proper sealing. This controlled environment is crucial for preventing contaminations.

Step #3: Injecting the Molten ZAMAK into the Die

Injecting the molten ZAMAK alloy into the die is critical in the die-casting process. In the previous step, engineers usually prepare and keep the molten metal in the injection chamber. Indeed, this chamber is well-sealed and controlled.

The injection device uses a plunger or piston to push the molten metal into the die. In this case, a certain pressure is necessary. Note that, based on this pressure rating, the type of die-casting may vary. However, the pressure forces the molten metal to reach every mold corner, filling the cavity.

FYI: Proper injection technique is crucial for high-quality castings. Additionally, it guarantees a smooth and even surface finish. Therefore, when designing a mold, the injection channel must be well-planned.

Step #4: Cooling and solidifying the die-cast ZAMAK parts

Once the molten ZAMAK alloys fill the die, cooling begins immediately. Since the mold is made of high-quality tool steel, it quickly draws heat away from the molten metal. However, the mold has a rapid cooling system that helps cool and solidify the molten ZAMAK parts.

Different types of cooling systems can be used in various situations. In this case, water and air cooling are the most popular options. These systems offer consistent cooling rates. It’s important to note that high-quality ZAMAK parts require consistent cooling rates.

FYI: A proper cooling system is always necessary for consistent solidification. It also helps in preventing many casting defects.

Step #5: Ejecting the Solidified ZAMAK Die-Casting Part

Once the ZAMAK alloy has solidified, it must be removed from the die. This step is typically called ejection.

FYI: An appropriate ejection ensures the part’s quality and integrity.

An ejector pin typically does this work. These pins help push the zinc casting part out of the die casting mold.

1. The die opens.
2. It separates into two halves.
3. The ejector pin activates.
4. They push against the casting. The casting is ejected out of the die.

The operator does it very carefully. It is evident that too much force can damage the part. Therefore, properly aligning the ejector pin avoids marks or dents on the final part.

Step #6 Finishing & Trimming

After ejection, the part typically leaves behind an excess part that requires trimming. These excess parts are also called flashes. These flashes generally hamper the performance of the die-cast ZAMAK parts.

Foundries use different trimming machines depending on the situation. Grinding or polishing machines help a lot here. Some small-scale foundries may do it manually. However, various surface treatments are implemented on ZAMAK die-casting parts for further finishing.

Step #7: surface treatment

As mentioned in the previous step, you can give a surface a premium look using various methods. Different surface treatment methods are used for varying application needs.

Surface treatment is the final step of the ZAMAK die-casting method. It mainly improves the aesthetics of the metal parts.

Zinc plating is one of the most common methods here. This process typically involves coating ZAMAK parts with another metal. Black nickel electroplating, chrome, and zinc are popular plating materials.

Another widely-used method is painting. Painting generally adds color and extra protection. Although painting is not as effective as other methods, it is cheap and easy. You can do it either by spray paint or powder coating. Note that powder coating is generally more durable and resistant to chipping.

Anodizing is another effective technique, though it is less famous than plating. It increases surface hardness and corrosion resistance, for example, some zamak 3 or zamak 5 die castings that use gold anodizing finish for some furniture components.

There are other methods available for surface analysis. However, each method described above has its unique advantages and limitations. The choice mainly depends on your project needs and budget.

Applications of ZAMAK Die Casting Parts

As you are already familiar with, ZAMAK die-casting parts offer many benefits. These pros make ZAMAK alloys perfect for many uses. This part will show some common ways ZAMAK die-casting parts are used. The following table highlights some common ZAMAK die-casting parts used in various industries.

Industries	Use Examples
Car Parts	Door handles, knobs, clusters, AC ventilators, sound systems, seat belt adjusting parts, engine components, starters, and car electronic gadgets.
Electronics Gadgets	Laptop castings and parts, tables, mobile phones, headphones, TV remotes
Hardware	Grips, levers, pulls, joints, drawer tracks, decorative furniture
Plumbing	Tap handles, showerheads, appliance dials, and switches, ornamental edging
Toys & sports items	Cast toy vehicles, mini trains, toy firearm parts, and sports gear parts.

Car Parts

The auto industry frequently uses ZAMAK die-casting parts. These metal parts are strong and accurate, which makes them ideal for making complicated car parts. They can also survive harsh conditions and are lightweight. These pros are necessary for your car’s fuel efficiency.

Electronic Equipment

ZAMAK parts are perfect for this industry. These alloys can be used to make a wide range of products. As you know, electric items create electromagnetic interference. ZAMAK die-casting parts provide an excellent shield against it.

Hardware and furniture

Another benefit of the ZAMAK die-casting parts is excellent adhesion. Because of this, you can typically give these parts a premium look. Therefore, ZAMAK die-casting parts are widely used in many aesthetic applications. This feature is critical in hardware and furniture.

Plumbing & Appliances

ZAMAK die-casting parts also resist corrosion. These metals offer excellent strength and malleability, making them durable. Therefore, ZAMAK parts are prevalent in plumbing and various appliances.

Toys and sporting goods

Finally, ZAMAK die-casting parts are widely used in the manufacturing of toys and sports items. It is ideal for making die-cast toy cars, model trains, and toy gun parts.

Zamak Die Casting vs Aluminum: Which is Better?

Let’s examine the capabilities of the better options. We summarize their characteristics in the following table, which can help you choose the suitable material for your project.

Aspect	ZAMAK die casting	Moulage sous pression d'aluminium
Matériau	Zinc, aluminum, magnesium, and copper	Mainly aluminum
Point de fusion	380°C to 1446°C	463°C to 671°C
Fluidity	Very high	High
Strength to Weight Ratio	High	Very high
Corrosion resistance	Moderate	Very high
Weight	Relatievly heavier	Lighter
Thermal conductivity	Plus bas	Higher
Electrical conductivity	Moderate	Higher
Hardness	95 to 115 Brinell	75 to 120 Brinell
Résistance à la traction	263 MPa to 317 MPa	290MPa to 325MPa
Limite d'élasticité	200MPa to 317 MPa	130 to 170 MPa

From the above table, you can see that ZAMAK die-casting parts offer some benefits. With the exception of ZAMAK 2, these die-casting parts boast a low melting point, excellent fluidity, and a high-quality surface finish. Therefore, they are ideal for use in the production of hardware and toys. Additionally, they offer low thermal and electrical conductivity. Therefore, ZAMAK die-casting parts are widely used in the production of many electronic gadgets.

On the other hand, aluminum die-casting parts give a high strength-to-weight ratio. Also, they offer high tensile strength, meaning you can use it to make many auto engine parts. Aluminum die-casting parts also provide high corrosion resistance. This makes them suitable for use in harsh weather conditions. Moreover, aluminum offers high thermal and electric conductivity. Therefore, aluminum is also used in electrical appliances. Go to the zinc vs. aluminum die casting page to learn more.

ZAMAK Die Casting Manufacturer: GC Precision Services

GC Precision Mold Co. Ltd is a top ZAMAK die-casting manufacturer globally. They also work with materials like aluminum, magnesium, and bronze. Besides die casting, they offer sand and investment casting services.

GC Precision also provides various CNC machining services. This precise machining process is responsible for the high quality of ZAMAK 3 and ZAMAK 5 die casting parts. Their advanced technology ensures excellent results for all casting and machining needs.

If you need any ZAMAK die-casting services, feel free to contact us. Our team of experts is always delighted to hear from you.

Frequently Asked Questions

How Durable Is ZAMAK?

ZAMAK’s durability is attributed to numerous factors:

1. It offers excellent corrosion resistance.
2. It has a decent hardness and tensile strength.
3. It offers a high strength-to-weight ratio.
4. It offers excellent adhesion.

Therefore, it allows for a variety of surface treatments. Overall, ZAMAK is a reliable and long-lasting material for industrial uses.

What Temperature Does ZAMAK Melt At?

The melting varies from grade to grade. For example, ZAMAK 2 melts at 1446 degrees centigrade, while ZAMAK 3-12 melts at 380 to 440 degrees Celsius. Except for ZAMAK 2, other grades have low melting points. It makes the alloy ideal for die casting. A low melting point also gives faster cycle times and lower energy costs.

What Is The Best ZAMAK For Casting?

The best ZAMAKs for die casting are ZAMAK 3 and 5.  They both are commonly used due to their excellent strength and flexibility. Die-cast ZAMAK 3 typically offers high fluidity and less shrinkage. On the other hand, the ZAMAK 5 die-casting alloy provides higher strength. It usually offers better hardness and tensile strength.

What is the lower limit for zinc die casting wall thickness?

The lower zinc die-casting wall thickness limit is 0.5 mm or 0.02 inches. As you know, ZAMAK offers excellent fluidity and strength. These two features generally hold thin walls without compromising strength.