Are you searching for a zinc alloy that combines high strength, excellent surface finish, and cost-effectiveness for your die casting projects? With so many materials available, choosing the right one can feel overwhelming — especially when your production deadlines and budgets are on the line.

That’s why manufacturers and procurement professionals around the world turn to Zamak 5. This widely used zinc alloy has become the industry standard for high-volume die casting, offering superior performance, reliability, and value.

By understanding the material and mechanical properties of Zamak 5, you can make smarter sourcing decisions, reduce production risks, and ensure your products meet the highest standards. Whether you’re in automotive, construction, or electronics, Zamak 5 gives you the flexibility and quality you need.

What Is Zamak 5?

Zamak 5 is a zinc-based alloy primarily used in precision die casting. It belongs to the Zamak family of alloys—a group of materials named from the German abbreviation for their key components: Zink (zinc), Aluminium, Magnesium, and Kupfer (copper). Among the Zamak series (which includes Zamak 2, 3, 5, and 7), Zamak 5 stands out for its superior strength and hardness, thanks to its slightly higher copper content.

As a zinc alloy, Zamak 5 typically contains:

• Zinc (~95%)
• Aluminum (~4%)
• Copper (~1%)
• Trace amounts of magnesium and iron

This carefully balanced composition gives zinc Zamak 5 exceptional fluidity during the die casting process, allowing it to fill even the most complex mold geometries with minimal shrinkage or distortion. That makes it especially ideal for parts that demand high dimensional accuracy and a fine surface finish.

Compared to Zamak 3, which is often considered the base standard, Zamak 5 offers:

• Higher tensile strength
• Better creep performance
• Slightly reduced ductility (a trade-off for increased hardness)

Zamak 5 Material Properties

The performance of Zamak 5 in industrial applications is rooted in its well-balanced material characteristics. This zinc alloy combines strength, fluidity, and corrosion resistance, making it one of the most versatile and cost-effective materials for die casting.

✅ Excellent Castability

Zamak 5 flows smoothly into detailed molds, making it ideal for high-precision and complex component designs. Its high fluidity reduces the need for secondary machining processes, saving time and cost.

✅ Dimensional Stability

Thanks to its low shrinkage rate and minimal warping during solidification, Zamak 5 maintains tight tolerances — a critical feature for parts used in mechanical assemblies and moving components.

✅ Corrosion Resistance

While not as corrosion-resistant as aluminum or stainless steel, Zamak 5 still performs well in most indoor or protected environments. The addition of copper improves strength but slightly reduces its resistance to corrosive atmospheres compared to Zamak 3.

✅ Surface Finish Quality

Zamak 5 accepts a wide range of finishes — from electroplating and powder coating to painting and chromating. This makes it a favorite for visible components in consumer goods and automotive interiors.

✅ Thermal and Electrical Conductivity

Zamak 5 exhibits moderate thermal and electrical conductivity, making it suitable for components that require minimal heat buildup or occasional electrical grounding.

Zamak 5 Mechanical Properties

One of the key reasons Zamak 5 is so widely used in die casting is its reliable and predictable mechanical properties. This zinc alloy delivers the strength and durability needed for many structural and functional components, without the higher costs of alternative materials like aluminum or stainless steel.

📏 Tensile Strength

• Ultimate Tensile Strength: ~331 MPa (48,000 psi)
• Zamak 5 has higher tensile strength than Zamak 3, making it better suited for parts that must withstand mechanical stress or external forces during use.

🔧 Yield Strength

• Yield Strength: ~280 MPa (40,600 psi)
• This ensures structural integrity under load, particularly for parts in machinery or support brackets.

💥 Impact Strength

• Zamak 5 has moderate impact resistance. While not as tough as magnesium or aluminum alloys, it offers sufficient durability for most industrial uses — especially when surface-finished.

🧱 Hardness

• Brinell Hardness: ~82
• The increased copper content gives Zamak 5 a harder surface compared to other zinc alloys, reducing wear over time.

📐 Elongation at Break

• Elongation: ~7%
• Zamak 5 sacrifices a small amount of ductility in favor of strength and hardness. It is less formable than Zamak 3, but still suitable for many designs that don’t require flexing or bending.

Common Applications of Zamak 5

Because of its excellent balance between strength, castability, and finish quality, Zamak 5 is widely used in a variety of industrial and commercial applications. From small mechanical parts to consumer-facing components, Zamak 5 offers the performance and efficiency manufacturers need.

🚗 Automotive Industry

• Door handles
• Interior trim components
• Carburetor and fuel system parts
• Electrical housings and connectors

The mechanical properties of Zamak 5—especially its high tensile strength and excellent dimensional stability—make it ideal for parts that require both precision and strength.

🏗️ Construction and Hardware

• Lock bodies and keys
• Hinges and brackets
• Window frames and accessories

With its smooth surface finish and compatibility with plating or painting, Zamak 5 is often used in decorative and functional building hardware.

🧑‍🌾 Agricultural Equipment

• Mechanical levers
• Gear housing
• Pump casings and handles

Agricultural tools benefit from the durability and corrosion resistance of Zamak 5, especially for parts that may be exposed to moderate environmental conditions.

🖥️ Electronics and Consumer Goods

• Enclosures for electrical devices
• Heat sinks
• Appliance components

Thanks to its thermal conductivity and excellent casting performance, Zamak 5 is used in many components that require both electrical insulation and mechanical strength.

🔩 Industrial Machinery

• Mounting plates
• Gear wheels
• Connector shells

The zinc Zamak 5 alloy is frequently chosen for mechanical parts where strength, wear resistance, and cost efficiency are essential — especially in high-volume production settings.

Advantages of Using Zamak 5 in Die Casting

When it comes to high-volume metal manufacturing, Zamak 5 offers a combination of technical performance and economic advantages that few other alloys can match. That’s why it remains one of the most trusted materials in global die casting operations.

⚙️ High Dimensional Accuracy

Zamak 5 allows for the production of complex parts with tight tolerances, reducing the need for secondary machining. This means faster lead times and lower manufacturing costs.

💸 Cost-Effective for Mass Production

Compared to aluminum or magnesium alloys, Zamak 5 is more affordable while still delivering reliable strength and durability. Its low melting point also reduces energy consumption during casting.

🎨 Excellent Surface Finish

The smoothness of Zamak 5 after casting makes it ideal for parts that will be electroplated, painted, or powder-coated. This is especially useful for visible components in consumer and automotive products.

🔁 Consistent Performance in Repetitive Casting

Zamak 5 performs well over long casting cycles, providing manufacturers with consistency and fewer defects—ideal for maintaining product quality and production efficiency.

🔒 Good Mechanical Strength

With superior tensile and yield strength over other Zamak alloys, Zamak 5 supports structural applications while offering improved wear resistance.

🌍 Environmentally Friendly

Zamak 5 is 100% recyclable without loss of material properties, making it a sustainable choice for companies focused on reducing environmental impact.

Conclusion

Zamak 5 offers an ideal balance of strength, precision, and affordability for die casting applications. Its proven performance across industries makes it a smart choice for manufacturers seeking reliable results and cost-effective production.