Melting Point of Zinc and Zamak Alloys - Reference Chart

Pure zinc melts at 419.5°C (787°F). Die casting zinc alloys - the Zamak and ZA families - melt slightly lower, across a narrow band around 380-390°C. That single number explains most of zinc die casting's advantages: hot-chamber machines, fast cycles, long die life, and fine detail reproduction all follow from how little heat the process has to manage.

This page is the quick reference: melting ranges by alloy, actual casting temperatures, and what the numbers mean when you are choosing between zinc and other metals.

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Melting Point Chart: Zinc Alloys Used in Die Casting

Alloys do not melt at one temperature. They soften at the solidus and finish melting at the liquidus, with a slushy two-phase zone between. The values below are typical published ranges:

Alloy	Solidus	Liquidus	Notes
Pure zinc	-	419.5°C (787°F)	Reference point - not a casting alloy
Zamak 2	~379°C	~390°C	Highest copper of the Zamaks; ages hardest
Zamak 3	~381°C	~387°C	The workhorse - most common zinc die casting alloy
Zamak 5	~380°C	~386°C	+1% copper; stronger and harder than Zamak 3
Zamak 7	~381°C	~387°C	Low-magnesium Zamak 3 variant; better fluidity for thin walls
ZA-8	~375°C	~404°C	8% aluminum; the only ZA alloy routinely hot-chamber cast
ZA-12	~377°C	~432°C	11% aluminum; hot or cold chamber
ZA-27	~375°C	~487°C	27% aluminum; strongest, coldest-chamber only

For composition and mechanical properties, see the individual alloy pages: Zamak 3, Zamak 5, ZA-8, ZA-12, ZA-27, or the full zinc die casting alloys overview.

Casting Temperature vs Melting Point

Foundries do not cast at the liquidus - they superheat the melt for fluidity. In production:

• Hot-chamber zinc die casting typically holds the pot around 400-430°C, with the metal injected somewhat below that depending on machine and part
• Thin-wall and miniature parts run toward the hotter end for fill; heavy sections run cooler to cut cycle time and shrinkage
• ZA-27, with its higher liquidus, runs hotter still - one reason it stays in cold-chamber machines

Rule of thumb for buyers: you never need to specify melt temperature. But you should understand that a part quoted at an unusually fast cycle time is partly a statement about how cool the process window lets the die run.

Why Zinc's Low Melting Point Drives the Whole Business Case

Hot-chamber casting is possible. At ~400°C the injection gooseneck can sit permanently submerged in the melt - no ladling, no separate shot chamber. Hot-chamber cycles are the fastest in die casting, and they only exist because zinc melts low enough for immersed iron components to survive. Aluminum (660°C) and magnesium (~650°C) force cold-chamber machines with slower, more complex shots. See hot chamber vs cold chamber die casting.

Dies last. Thermal fatigue kills dies, and zinc's low pouring temperature is gentle. Zinc dies routinely outlast aluminum dies by a wide margin - which is why tooling amortization on long-running zinc programs looks so good.

Cycles are short. Less heat in means less heat out. Solidification happens fast, so ejection comes sooner and parts-per-hour climbs - the core of zinc's unit-cost advantage at volume.

Detail and thin walls come easier. Low process temperature pairs with excellent fluidity: zinc fills sub-millimeter walls, fine ribs, and sharp cosmetic detail that aluminum struggles to fill. That is why miniature and precision hardware defaults to zinc.

Energy and melt loss stay low. Lower temperatures mean less gas, less dross, and less furnace wear. It shows up quietly in the piece price.

Zinc vs Other Casting Metals: Melting Points in Context

Metal / alloy family	Melting range	Process consequence
Zinc (Zamak)	~380-390°C	Hot chamber, fastest cycles, longest die life
Magnesium (AZ91D)	~470-595°C (cast ~650°C)	Cold/hot chamber both exist; needs melt protection
Aluminum (A380)	~540-595°C (pure Al 660°C)	Cold chamber only; harder on dies than zinc
Brass	~900-940°C	Punishing on dies - rarely die cast; see brass die casting
Steel	~1,370-1,510°C	Not die castable at all - see steel die casting

The pattern: every 100°C of melting point costs you something - machine type, cycle time, die life, or the process entirely. Zinc sits at the forgiving end of the table.

Practical Takeaways for Buyers

1. Ask "which zinc alloy," not "which melting point." The Zamak-vs-ZA choice is made on strength, ductility, and castability - what is Zamak and Zamak 3 vs Zamak 5 walk through it.
2. Melting point is why zinc wins small precision parts. If your part is under ~500 g with fine detail or thin walls, zinc's process economics are hard to beat.
3. High service temperature is zinc's weak side. Creep resistance drops well below the melting point - sustained loads above roughly 100°C need a conversation about aluminum or ZA alloys instead. Melting point is a process number, not a service-temperature rating.
4. Plating loves zinc castings. The as-cast surface that low-temperature casting produces is why decorative chrome hardware is overwhelmingly zinc.

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Frequently Asked Questions

What is the melting point of Zamak 3?

Zamak 3 melts across a narrow range of roughly 381-387°C (solidus to liquidus), versus 419.5°C for pure zinc. The aluminum, magnesium, and trace copper in the alloy depress and spread the melting point.

At what temperature is zinc die cast?

Melting happens around 380-390°C, but production casting uses superheat: hot-chamber machines typically hold the melt at about 400-430°C for good fluidity. Exact settings depend on alloy, wall thickness, and machine.

Does zinc melt at a lower temperature than aluminum?

Yes - dramatically. Zamak alloys melt around 380-390°C while A380 aluminum melts around 540-595°C. That gap is why zinc can use fast hot-chamber machines and why zinc dies last so much longer.

What is the highest-melting zinc die casting alloy?

ZA-27, with a liquidus around 487°C - high enough that it requires cold-chamber machines. Its 27% aluminum content buys the best strength and elevated-temperature performance of the zinc family.

Can zinc die castings handle high service temperatures?

Melting point is not the limit - creep is. Zamak alloys lose strength under sustained load well above room temperature; continuous service near or above ~100°C calls for ZA-27, aluminum, or a design review. Never size a zinc part against its melting point.

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Related Reading

• what is Zamak - the alloy family explained
• zinc die casting - KastMfg zinc capability
• zinc die casting alloys - full selection guide
• hot chamber vs cold chamber die casting - what melting point decides
• aluminum vs zinc die casting - choosing between the two families

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