Zinc alloy has a low melting point, good fluidity; easy welding; good mechanical; and corrosion resistance in the atmosphere; therefore it is be weld used on industry. as a result the process produce Zinc parts called Hot chamber die casting; Zamak 3 and Zamak 5 is zinc alloy ingot; as has been noted they have different character; but what is difference between zamak 5 and zamak 3? lets explore more on them.
What is Zamak?
ZAMAK is a family of alloys which has a base metal of zinc and alloying element of aluminum;magnesium and copper. New Jersey in 1929 invented zamak alloy. ZAMAK is an abbreviation of German name for the metals of which the alloys are composed: Zink (Zink) Aluminium Magnesium and Kupfer copper alloys. These alloys (especially #3s and #5) are often used for the Die Casting industry.
Zamak 3 and Zamak 5 Chemical Composition
| Element | Zamak 3 Content(%) | Zamak 5 Content(%) |
|---|---|---|
| Aluminum, Al | 3.5-4.3 | 3.5-4.3 |
| Copper, Cu | 0.25 | 0.75-1.25 |
| Magnesium, Mg | 0.02-0.05 | 0.02-0.05 |
| Iron, Fe | 0.1 | 0.1 |
| Lead, Pb | 0.005 | 0.005 |
| Cadmium, Cd | 0.004 | 0.004 |
| Tin, Sn | 0.003 | 0.003 |
| Zinc | Balance | Balance |
Zamak 3 and Zamak 5 Physical Properties
| Properties | Metric | Imperial |
|---|---|---|
| Density | 6.6 g/cm3 | 0.24 lb/in3 |
| Melting point | 380-386°C | 717-727°F |
Mechanical Properties
Zamak 3 alloy
| Properties | Metric | Imperial |
|---|---|---|
| Tensile strength | 268 MPa | 38900 psi |
| Yield strength | 208 MPa | 30200 psi |
| Modulus of elasticity | 96 GPa | 14000000 psi |
| Elongation at break | 10% | 10% |
| Brinell hardness | 82 | 82 |
Zamak 5 alloy
| Properties | Metric | Imperial |
|---|---|---|
| Tensile strength | 331 MPa | 48000 psi |
| Yield strength | 295 MPa | 43000 psi |
| Modulus of elasticity | 96 GPa | 14000000 psi |
| Elongation at break | 7% | 7% |
| Brinell hardness | 91 | 91 |
Thermal Properties
| Properties | Zamak 3 Metric | Zamak 5 Metric |
|---|---|---|
| Thermal conductivity | 113 W/mK | 109 W/mK |
Zamak 3 Equivalent
| Ingot | Common | ASTM | JIS | GB | BS | NFA | DIN | UNS |
|---|---|---|---|---|---|---|---|---|
| Zamak 3 | Alloy 3 | AG40A | ZDC 2 | ZX01 | Alloy A | Z-A4 | Z400 | Z35520 |
Zinc Die Casting alloy Advantage
1. Relative specific gravity.
2. Good casting performance, can die-cast complex shape, thin-walled precision parts, smooth casting surface.
3. Surface treatment: electroplating, spraying, painting, polishing, grinding, etc.
4. No iron absorption when melting and die-casting, no corrosion of the die casting die, no sticky die.
5. have very good room temperature mechanical properties and wear resistance.
6. low melting point, melting at 385℃, easy to die-casting molding.
Zinc Die Casting Alloy Disadvantage
The most common defect of zinc alloy die casting is surface blistering.
Defects characterization: die casting surface has raised small bubbles; Mainly manifested as:
A. die-casting Parts come out of die with Porosity
B. polishing or processing revealed
C. After oil spraying or plating.
How can we reduce the disadvantages of zinc alloy die casting and improve its accuracy?
1, we have Multi-Slide and Conventional Die Casting machine. We determine the model according to the different requirements of different products.
2, we will do DFM parting in the mold design stage, and use computer-aided technology to predict the position of air bubbles and how to improve them in advance.
3. In the surface treatment stage of the product, we can strengthen the process control to improve the product yield rate.
4. With the help of CCD visual inspector, 100% full inspection, reduce the flow of defective products
Zinc Die Casting Applications
Now more and more industry are using zinc alloy material for their parts, such as in below industry.
Decoration Parts
Industry Parts
communication parts
Automotive parts
Consumer Parts
Blenders