This article delves into the key characteristics of Zamak 3, including its chemical composition, mechanical properties, application areas, and comparisons with other zinc alloy die casting materials. We will also explore its advantages and limitations to help you make an informed decision for your next die casting project.
Main Elemental Composition
Zinc (Zn)
Comprising approximately 95%, zinc serves as the primary component, forming the structural foundation of Zamak 3.
It ensures good mechanical properties while keeping manufacturing costs low for large-scale production.
Aluminum (Al)
At around 4%, aluminum enhances the strength and rigidity of Zamak 3, improving its corrosion resistance and making the alloy more durable in harsh environments.
Magnesium (Mg)
Present at about 0.03%, magnesium improves castability, refines the grain structure, enhances fluidity, and reduces casting defects, ensuring high precision in zinc die casting components.
Copper (Cu)
With a content of about 0.1%, copper increases hardness and wear resistance, making Zamak 3 ideal for parts that need to endure friction and mechanical stress.
Comparison with Other Zamak Alloys
Zamak 2
Containing about 3% copper, Zamak 2 offers higher hardness and wear resistance than Zamak 3, making it suitable for high-load applications such as gears and bearings.
However, its lower ductility limits its use in applications requiring flexibility.
Zamak 5
With approximately 1% copper, Zamak 5 is stronger and harder than Zamak 3, making it ideal for structural parts requiring greater load-bearing capacity, such as automotive accessories.
However, its slightly lower fluidity makes it less suitable for casting intricate zinc die casting components.
Zamak 7
Zamak 7 has a lower magnesium content than Zamak 3, enhancing its fluidity and making it suitable for high-surface-finish applications such as electronic housings.
However, its slightly lower mechanical strength makes it less suitable for load-bearing components.
Mechanical and Physical Properties
Mechanical Properties
Zamak 3 maintains good mechanical strength in its cast state, with excellent dimensional stability and moderate hardness for sufficient wear resistance.
It also has enough ductility to withstand stress without breaking. The following are the mechanical properties of Zamak 3 as-cast:
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Tensile Strength: 280 MPa
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Yield Strength: 220 MPa
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Hardness: 82 HB
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Elongation: 10%
Physical Properties
Zamak 3 has a relatively high density, making it heavier than aluminum alloys but lighter than steel.
Its low melting point supports low-temperature die-casting processes, improving production efficiency.
In addition, its moderate thermal and electrical conductivity can be used in applications that require a certain amount of heat dissipation.
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Density: 6.6 g/cm³
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Melting Point: 380°C – 390°C
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Thermal Conductivity: 113 W/m·K
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Electrical Conductivity: 27% IACS
Advantages of Zamak 3 in Die Casting
High Precision and Stability
With a low shrinkage rate, Zamak 3 maintains precise dimensions and shapes after cooling, reducing the need for secondary machining.
Excellent Fluidity
The superior fluidity of Zamak 3 allows it to fill intricate mold structures, making it ideal for detailed designs and thin-walled zinc die casting components.
Superior Surface Quality
Zamak 3 produces castings with smooth surfaces, minimizing the need for post-processing and making it ideal for painting, plating, and other surface treatments.
Suitable for Large-Scale Production
Zamak 3’s low melting point and efficient casting process reduce production costs, while minimal material loss enhances economic efficiency for mass production.
Strong Machinability
Zamak 3 is easy to machine and can easily perform drilling, tapping, and turning with minimal tool wear, extending the lifespan of processing equipment.
Common Applications of Zamak 3
Automotive Industry
Zamak 3 is widely used for brackets, housings, door handles, trim components, gear lever assemblies, dashboard parts, and door hinges.
These zinc die casting components require high precision, durability, and aesthetic appeal.
Electronics and Electrical Components
Thanks to its conductivity and corrosion resistance, Zamak 3 is used in electronic housings, heat sinks, connectors, plugs, switch components, and motor end covers.
Its die-casting properties meet the demand for miniaturization and precision in electronic devices.
Consumer Hardware
Zamak 3 is used to manufacture door handles, lock cylinders, hinges, fasteners, zippers, picture frames, and furniture fittings.
These products require both strength and high-quality surface finishes for durability and aesthetics.
Industrial Machinery
In the industrial sector, Zamak 3 is ideal for gears, cams, handles, clamps, fasteners, pump housings, and mechanical accessories.
These zinc die casting components demand precision, stability, and mechanical load resistance.
Equivalent Materials of Zamak 3
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ASTM (USA): AG40A
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DIN (Germany): ZL0400
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JIS (Japan): ZDC2
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ISO (Global): ZnAl4
Alternative Zinc-Based Alloys
ZA-8
With approximately 8% aluminum, ZA-8 offers higher strength and wear resistance than Zamak 3 but has reduced fluidity, making it less suitable for complex castings.
ZA-12
Containing around 12% aluminum, ZA-12 provides enhanced strength and wear resistance but is more challenging to machine and has higher production costs.
Challenges and Limitations of Zamak 3
High-Temperature Resistance
Zamak 3 is not suitable for prolonged exposure to high temperatures, as excessive heat can weaken its mechanical properties.
Corrosion Resistance
Although Zamak 3 offers relatively good corrosion resistance, it may be susceptible to oxidation in high-humidity, acidic, or saline environments.
Protective coatings or plating may be necessary for extended durability.
Mechanical Strength
While Zamak 3 meets most application needs, its tensile strength and hardness are slightly lower than Zamak 5.
For applications requiring higher mechanical performance, alternative zinc alloy die casting materials should be considered.
Conclusion
Zamak 3 has become a widely used zinc alloy die casting material due to its excellent castability, cost-effectiveness, and balanced mechanical properties.
It plays an important role in many industries such as automobiles, electronics, and consumer goods.
As an industry-leading zinc die casting components manufacturer, CEX Casting is committed to producing high-quality die casting parts.
Contact us now to learn how CEX can provide end-to-end solutions for your next die casting project.