What Is Zamak Material?
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| Zamak Material |
Zamak material is an alloy made from a composition of zinc, magnesium, copper and aluminium where zinc is the base metal having 95% composition.
It has a bright silver surface finish texture which makes this metal applicable for use in decorative objects such as handles for drawers, cars, cupboards and wardrobes.
This metal is best for small-size casting products that are complex in shape and design such as shooter ballet, idols and figures, toys such as cars, trains, and aeroplanes and jewellery such as rings, bracelets, earrings, pendants and neckless, hooks, zipper, luxury gifts, tooling and knobs.
Casting produced from this metal is light in weight, small sections can be produced and thin wall casting with a superior surface finish can be mass-produced.
It has a higher melting point than the pewter metal used in the casting process but lower than aluminium and stainless steel.
Other metals that can be added to improve its mechanical properties are silicon, nickel, tin, cadmium, iron and lead. The use of lead and cadmium has been eliminated in recent times and efforts are made to make products toxic-free.
This metal can be powder coated, wet painted, chrome plated and galvanised coating of chromium, brass and silver making the casting and products manufactured attractive, decorative and visually appealing for design ornaments.
Small to medium-sized complex casting with a high surface finish at higher volume can be produced using a die-casting process using zamak metal.
Why name Zamak material is given to the metal?
The name zamak is derived from the metal initials used in the material. Z (Zinc), A (Aluminium), MA (Magnesium) and K (Kuper, meaning Copper in the German language).
Is Zamak a good metal?
It is a high-quality zinc-based alloy metal made from zinc, aluminium, magnesium and copper used for manufacturing casting using spin casting and die casting process used to produce bearings, rails, bottle caps and frames.
In which manufacturing process is zamak material used?
Zamak type 3 metal is used in the high-pressure die-casting process, centrifugal casting process and hot chamber die-casting process for manufacturing automotive components, decorative hardware, plates, rollers, bearings, hinges, toys, door handles, sports equipment (golf handles) and electronic connectors.
The sand casting process is mostly used by small foundries and hobbyists.
Is zamak metal strong aluminium?
There is no single answer to this question, this answer depends upon the application, force induced on the metal, type of force, working condition, factor of safety and design weakness.
The tensile strength of this material goes up to 400 N/㎟ while the tensile strength of aluminium can reach 570 N/㎟ making aluminium stronger than zamak when it comes to loading the metal in pull applications where tensile force is applied in products such as grab handles.
The compressive strength of this metal and aluminium can be achieved up to 500 N/㎟. Making both metal performers the same under compressive loading.
For ultimate tensile strength (UTS) of aluminium can go up to 570 N/㎟ while for this metal we can only reach up to 400 N/㎟ making aluminium stronger when subjected to this kind of loading.
Products are never designed solely based on the strength value but on the final application and type of forces induced in the product while using it.
How is the zamak material cleaned?
Zamak products can be cleaned with clean water, baking soda and lemon juice.
Zamak Material Type
This material is available in 5 types namely zamak-2,3,4,7 and 8. Details of every type are as follows:
Zamak-2 Material
Highly ductile metal has high castability so that metal can flow in small die sections making this type of metal best for making the following objects.
Zamak-2 Uses
- Complex intricate decorative hardware components.
- Pull handles for windows.
- Curtain rods.
- Fixtures.
- Parts of the car dashboard and interior.
- Electrical wire connectors.
- Housing components.
- Electronic enclosers and fittings.
The castability of this metal is high making it suitable for die-casting process and centrifugal casting process.
Zamak-2 Properties
- High castability and flowability of metal.
- Complex design casting can be cast in die mould.
- The shine on the product is superior for decorative hardware products.
- The density and durability of the casting are superior.
- Accurate casting with good surface texture can be produced with excellent dimensional stability used to produce fashion jewellery silver plated sets, beads rolls, bangles, crowns and tiaras.
Zamak-2 Composition
| Zamak Type | Metal Composition |
|---|---|
| Zamak-2 | This metal has a composition of 95% zinc, 4% aluminium, 0.6% copper and remaining magnesium. |
Zamak-3 Material
- Used in the fashion industry to produce versatile products, apparel and accessories.
- Gold electroplated perfume bottle caps, heads and casing.
- Logos, badges. emblems, chrome door protection edges, plates and grills.
Zamak 3 Composition
| Zamak Type | Metal Composition |
|---|---|
| Zamak-3 | This metal composition has 96% zinc, 3.7% aluminium, 0.7% copper and remaining magnesium. |
Zamak-5 Material
This metal has load-bearing capacity making it best for brackets, hinges, stands, machine bases, fasteners, automotive chassis parts and structural supports.
This metal is more ductile than type-3 reducing the ability of the metal during bending, swaging, spinning, forming and drawing operations.
The tensile strength of this material is better than type-3 material so this metal is better for products that are undergoing tensile loading but have less dimensional accuracy while producing complex shapes as mouldability and malleability reduce with increasing in strength.
Also have superior corrosion resistance properties.
Zamak 5 Composition
- Car decorative trims.
- Deck accessories and fittings of yachts, ships and boats.
- Pulleys and hardware components.
- Forklift and airbag parts.
- Blenders decor.
| Zamak Type | Metal Composition |
|---|---|
| Zamak-5 | The composition of this metal is 95% zinc, 4.3% aluminium, 1% copper and the remaining % is magnesium. |
Magnesium (Mg) improves the grain size of the casting refining it, reducing the formation of intermetallic compounds and improving the mechanical properties and surface texture of the casting.
Zamak-7 Material
This metal has good mechanical strength, strength and hardness with an increase in aluminium content allowing engineers to produce thin wall casting sections. Nickle is added in small quantities to reduce intergranular corrosion. This metal is very common in producing the following objects.
- Nuts, bolts and fasteners.
- Autotive parts and compoenents.
- Safety types of equipment.
Zamak-7 Composition
| Zamak Type | Metal Composition |
|---|---|
| Zamak-7 | This metal has a composition of 91.5% zinc, 7% aluminium, 1% copper and remaining magnesium. |
Aluminium (Al) allows flowability and castability of the molten metal entering the mould cavity improving mechanical strength and hardness of the final product with good dimensional accuracy.
The hardness of the final casting product needs to increase which cannot be increased by aluminium only that is why copper is added to the composition of metal.
Zamak-8 Material
This metal has good mechanical strength with an increase in aluminium content as compared to types 2,3,4 and 5.
This metal finds its application in the following products such as gears, and levers, because of high hardness and wear and tear resistance as these metal components have high operational life.
Zamak-8 Composition
| Zamak Type | Metal Composition |
|---|---|
| Zamak-8 | This metal has a composition of 91.5% zinc, 8% aluminium, 0.4% copper and remaining magnesium. |
Copper (Cu) increases the tensile strength of the final product improving toughness, machinability, dimensional stability, wear resistance and dimensional stability under load.
Theoretically, aluminium (Al) in this metal needs to be around 4%. Less than 4.5% aluminium content in the zamak will reduce the strength of the final component. Increasing aluminium by more than 4.5% will reduce tensile strength and increase the metal's hardness.
Keeping aluminium at 4% of the total composition is advised. Aluminium will increase strength and fluidity holding the base metal (zinc which is 90%) intact.
But it is not possible for every application, that is why change in the other metal elements such as copper, zinc, magnesium and aluminium.
Zamak Material Properties
What are the properties of zamak material?
- Metal Strength: All types of strength of the metal are high making this metal suitable for load applications such as brackets, engine parts, housing casing, hinges and pullers. The strength values of this metal are as follows:
- Tensile strength (330 N/㎟ or 47.86 ksi)
- Compressive strength (600 N/㎟ or 87.02 ksi)
- Shear strength (180 N/㎟ or 26.10 ksi to 200 N/㎟ or 29.00 ksi)
- Ultimate tensile strength (210 N/㎟ or 30.45 ksi to 350 N/㎟ or 50.76 ksi)
- Bending strength (190 N/㎟ or 27.55 ksi to 350 N/㎟ or 50.76 ksi)
- Hardness (90 BHN)
- Low melting point: The melting point of this metal is around 380℃ or 716℉ better than steel and aluminium consuming less energy for casting production.
- Metal Density: The density of this metal is 6.6 g/㎤ to 7.5 g/㎤ better than zinc, aluminium, iron and copper.
- Thermal conductivity: Metal has a thermal conductivity of 116 W/m-K having good heat dissipation quality that is required during the soldification process of casting in die.
- Recyclable: This metal is a zinc-based alloy able to recycle casting products by melting alloy metal reducing the environmental impact and reducing carbon footprint.
- Corrosion resistance: Metal has corrosion resistance properties and does not result in tarnish appearance as we see in the pewter metal.
- Lightweight: Lightweight product used in hander rings, decor, automobile, construction and marine industry.
- Mass production: Die casting, centrifugal casting and spin casting process are used to mass-produce casting in large volumes in smaller lead time.
- Surface Finish And Texture: Better surface finish and texture than pewter, aluminium and copper. This metal has an end silver finish.
- Castability, Machaniability And Flowability: Metal is castable at low temperatures and able to flow in small sections of die sections and able to produce complex casting products. The machinability of this metal is good and the desired product can be shaped on lathe machines and milling machines.
- Ductility And Malleability: The material is ductile and malleable and able to mould into different complex shapes and sizes by small force using a die and punch.
- Secondary Manufacturing Process: The secondary machining requirement is less for these metals especially when it comes to machining operation.
- Wear, Impact And Shock Resistance: Metal is wear-resistant and able to use shock and impact resistance applications.
- Internal Stress: Stressed induced during casting solidification is less improving casting quality as hotspot defects are reduced.
- Toxicity-Free Metal: Modern zamak metal is free from cadmium and lead and user-friendly for producing toys, bottle caps, tableware and kitchenware.
- Surface Appearance: The external surface of the metal can be plated with chrome, silver, brass, wet pained, rose gold plating, electroplating, powder coating and galvanizing to use in home decor, fashion industry, gift packing and car trims.
Zamak Material Specification
What is the specification of the zamak material?
Specification of Zamak material is ASTM B86/B86M where ASTM means American Society for Testing Materials. B86 stands for zinc and zinc-based alloy element metal. M stands for the metric unit used for international standards.
Zamak Material Use
What are the applications, uses and examples of zamak material?
Zamak material finds application in the machine industry, power distribution industry, automobile industry, marine industry, medical industry, telecommunication industry, cosmetic industry and consumer electronic industry.
- Handles of doors, furniture, kitchen cabinets, bathroom fittings and closet.
- Flanges, screws and valves.
- Crome-plated faucet handles.
- Fitting caps, connector housing and covers.
- Lock, nobs, latches and metal bookmark.
- Parts of household appliances, kitchenware and musical instruments.
- Wheel rollers, wheel spacer, racks and buttons.
- Mounting brackets, angle plates and fasteners.
- Luxury perfume bottle locking screw caps and lipstick casings.
- Bottle stopper of spirit bottles.
- Watch belts and luxury belts.
- Miniatures and custom figures.
- Earings and chokers.
- Bumper protecting chrome guards.
- Machine parts, ingots and bars.
- Handles of pursues, clutches and bags.
- Cover of instrumental, intercom body and electronic panels.
- Lamb base and stand.
- Lighting accessories.
- Cord ends and connectors.
- Lock and key sets.
- Nose pin and earpin.
- Engine and alternator housing.
- Buckels of shoes.
- Vintage-looking engraved jewellery, findings and clasps.
- Gold, silver and bronze-plated medals.
- Home decor, casting pipes and hoses.
Zamak Material Advantages
What are the advantages of zamak?
- Has corrosion resistance properties.
- Gives a bright silver metal appearance and finish.
- Can be easily electroplated, painted, coated, decorative finished, grinding and polished to bring aesthetically appealing shine, texture and finish.
- Can be machined on a lathe machine and milling machine.
- Grinding, lapping and buffing operations can be performed to shine the products.
- Environmentally friendly and recyclable metal.
- As the melting point of metal is low life and durability of die moulds is high.
- Metal has anti-allergic and anti-bacterial properties.
- The machining required for this metal is less as it is so mouldable in metal dies/moulds.
- Have higher vibration and dumping capacity than aluminium metal.