What Is Zamak? Zinc Alloy Family Explained
What is Zamak? The zinc-aluminum alloy family (Zamak 2, 3, 5, 7) explained: composition, properties, uses, and why it dominates hot-chamber die casting.
Mike Yao
Technical Director, Die Casting Engineering
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Zamak is a family of zinc-aluminum die casting alloys - roughly 96% zinc with about 4% aluminum, plus small amounts of magnesium and (in some grades) copper. The name comes from the German initials of its ingredients: Zink, Aluminium, MAgnesium, Kupfer (copper). If you have touched a car door handle, a zipper pull, a lock cylinder, or a chrome cabinet knob today, you have almost certainly touched Zamak.
What Is in Zamak?
| Element | Typical content | What it does |
|---|---|---|
| Zinc (Zn) | ~95 to 96% | Base metal - castability, corrosion behavior, weight |
| Aluminum (Al) | ~4% | Strength, hardness, and fluidity |
| Magnesium (Mg) | 0.02 to 0.05% | Grain refinement, counters impurities |
| Copper (Cu) | 0 to 3% (by grade) | Strength, hardness, creep resistance |
The family has four common grades, differing mainly in copper content:
| Grade | Copper | Character |
|---|---|---|
| Zamak 3 | 0% | The global default - best ductility and plating |
| Zamak 5 | 1% | Stronger, harder; Europe's standard |
| Zamak 2 | 3% | Highest strength and creep resistance |
| Zamak 7 | Near-0% (high purity, low Mg) | Extra fluidity for thin, fine-detail castings |
Why Zamak Dominates Hot-Chamber Die Casting
Zamak's melting range of roughly 380 to 390°C is the secret. That is low enough to run in hot-chamber die casting machines, where the injection mechanism sits in the molten metal - giving cycle times often under 30 seconds, the fastest in the casting industry. Aluminum cannot do this (it attacks the machine's iron parts), which is why aluminum needs slower cold-chamber machines.
The result: Zamak parts combine near-plastic cycle speeds with metal strength, at dimensions accurate to ±0.05 mm and surfaces with excellent response to decorative chrome plating.
What Is Zamak Used For?
- Hardware: locks, hinges, handles, zippers, buckles
- Automotive: door handles, lock housings, emblems, interior mechanisms
- Electronics: connectors, shielding frames, small enclosures
- Plumbing and appliances: faucet bodies, valve handles, knobs
- Furniture fittings: connectors, brackets, decorative fittings (see furniture hardware die casting)
Zamak's Honest Limitations
- Heavy: 6.6 g/cm3 - about 2.4x aluminum. Weight-sensitive parts go aluminum
- Temperature ceiling: properties fade above roughly 95 to 100°C service
- Not structural-ductile: 3 to 13% elongation depending on grade - it is strong, not tough
- Impurity-sensitive: lead, tin, and cadmium contamination above tiny limits causes intergranular corrosion ("zinc pest"), which is why certified ingot sourcing matters
For higher strength or temperature needs, the ZA family (ZA-8, ZA-12, ZA-27) raises aluminum content to 8 to 27% - at the cost of hot-chamber compatibility.
Frequently Asked Questions
Is Zamak a metal or a plastic?
A metal - a zinc alloy. Its smooth, plated finishes sometimes make people assume plastic; the weight gives it away.
Is Zamak safe and RoHS compliant?
Yes. Certified Zamak ingot meets RoHS and REACH. The alloy contains no lead above trace limits and is fully recyclable.
Zamak vs aluminum - which is better?
Neither - they serve different parts. Zamak wins for small, precise, plated, high-volume parts. Aluminum wins for larger, lighter, or hotter-running parts. Our aluminum vs zinc die casting guide walks the decision.
Does Zamak rust?
Zamak does not rust (that is iron's problem), but it can corrode in humid or outdoor service without plating or coating - which is why most Zamak parts are chrome plated, nickel plated, or powder coated.
Related Guides
- zinc die casting - KastMfg zinc capability
- zinc die casting alloys - full alloy selection guide
- Zamak 3 vs Zamak 5 - the two most common grades compared
- zinc die casting applications - industry use cases
- melting point of zinc - Zamak melting ranges and casting temperatures
Zamak part inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China
About The Author
Mike Yao on what is zamak
Technical Director, Die Casting Engineering
Technical Director at KastMfg with 20+ years in high-pressure die casting, leading engineering and program management across aluminum, zinc, and magnesium programs for automotive, EV, electronics, and medical OEMs worldwide.
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