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Where strength is concerned, ZAMAK- 5 is the logical choice and with its higher copper content resulting in higher strength and increased hardness at the expense of some loss of ductility (increased elongation) compared to Alloy 3. This reduction in ductility can affect formability during secondary operations such as bending, riveting, swaging or crimping operations and should be carefully considered by the designer.
Zamak 5 has the same composition as zamak 3 with the addition of 1% copper in order to increase strength (by approximately 10%), hardness and corrosive resistance, but reduces ductility.It also has less dimensional accuracy. Zamak 5 is more commonly used in Europe.
Zamak 2 has the same composition as zamak 3 with the addition of 3% copper in order to increasestrength by 20%. Zamak 2 has the greatest strength out of all the zamak alloys. Over time it retainsits strength and hardness better than the other alloys; however, it becomes more brittle, shrinks,and less elastic.
Zamak 2 is also known as Kirksite when gravity cast for use as a die. It was originally designed for lowvolume sheet metal dies. It later gained popularity for making short run injection molding dies. It isalso less commonly used for non-sparking tools and mandrels for metal spinning.
This alloy exhibits excellent damping capacity and vibration attenuation in comparison withaluminum die casting alloys. High strength and hardness levels after long-term aging.
Zamak 3 is the de facto standard for the zamak series of zinc alloys; all other zinc alloys are compared to this. Zamak 3 has the base composition for the zamak alloys (96% zinc, 4% aluminium). It has excellent castability and long term dimensional stability. More than 70% of all North American zinc die castings are made from zamak 3.
Zamak 3, or Zinc Alloy 3, is usually the first choice when considering zinc for die casting. Its excellent balance of desirable physical and mechanical properties, superb castability and long-term dimensional stability are the reasons why most die castings are made from this alloy. Zamak 3 also offers excellent finishing characteristics for plating, painting and chromate treatments.
