In zinc die casting, two alloys dominate: Zinc Alloy #3 (commonly known as Zamak 3) and Zinc Alloy #5 (Zamak 5). These high-purity zinc-based materials, primarily composed of zinc with about 4% aluminum and small amounts of magnesium, are essential for producing precise, complex parts in industries ranging from automotive to consumer electronics. While both offer excellent castability, low melting points, and superior surface finishes, their differences in composition drive distinct performance characteristics.
#3 Zinc Alloy vs #5 Zinc Alloy
Die Casting Part Prices
The primary distinction lies in copper content. Zinc Alloy #3 has minimal copper (typically less than 0.03%), making it the most widely used alloy in North America—accounting for over 70% of zinc die castings. Zinc Alloy #5, prevalent in Europe, incorporates 0.7-1.1% copper, boosting certain mechanical properties at the expense of others.
Mechanically, #5 outperforms #3 in strength and hardness. Typical tensile strength for #3 is around 283 MPa, compared to 310-317 MPa for #5. Zinc #5 also exhibits higher yield strength (around 240 MPa vs. 221 MPa for zinc #3) and Brinell hardness (90-91 vs. 82). These enhancements make zinc #5 ideal for high-stress applications, such as automotive components, hardware fittings, and structural parts requiring wear resistance and creep performance. However, zinc #3 provides better ductility and elongation, reducing brittleness and improving performance in applications needing flexibility or impact resistance.
In Zinc Diecastings, Castability favors zinc #3, which boasts superior fluidity for thin-walled, intricate geometries with minimal porosity. zinc #5’s copper addition can slightly increase porosity if not tightly controlled, though it offers marginally better plating and finishing qualities. Dimensional stability remains excellent for both, with zinc #3 holding a slight edge in long-term precision.
Cost is another factor: Zinc#3 is generally more economical due to lower copper levels and broader availability, making it the default choice for general-purpose components like electrical housings, toys, and decorative hardware. Zinc#5’s premium pricing (often 5-10% higher) is justified in demanding scenarios.
Corrosion resistance is comparable, though zinc#3 performs better in copper-sensitive environments. Both alloys excel in surface treatments like chrome plating, painting, and powder coating.
For a Zinc Die Casting Company Alloy #3 remains the versatile, cost-effective standard for most applications, while Zinc Die Casting Alloy #5 provides enhanced strength and durability where performance demands it. Choosing between them hinges on balancing mechanical needs, design complexity, and budget in modern manufacturing.
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