Zamak (formerly trademarked as ZAMAK[1] and also known as Zamac) is a family of alloys with a base

metal of zinc and alloying elements of aluminium, magnesium and copper. Zamak alloys are part of
the zinc aluminium alloy family; they are distinguished from the other ZA alloys because of their constant
4% aluminium composition.[2] The name zamak is an acronym of the German names for the metals of
which the alloys are composed: zink (zinc), aluminium, magnesium and kupfer (copper).[2] The New Jersey
Zinc Company developed zamak alloys in 1929. It may be referred to as pot metal or white metal.
The most common zamak alloy is zamak 3, but zamak 2, zamak 5 and zamak 7 are still commercially
used.[2] These alloys are most commonly die cast.[2] Zamak alloys (particularly #3 and #5) are frequently
used in the spin casting industry.
A large problem with early zinc die casting materials was zinc pest, owing to impurities in the
alloys.[3] Zamak avoided this by the use of 99.99% pure zinc metal, produced by New Jersey's use of
a refluxer as part of the smelting process.
Zamak can be electroplated, wet painted, and chromate conversion coated well.[4]

Zamak 3
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.[2]
Zamak 3 composition per standard
Alloying elements Impurities
†
Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl
min 3.9 - 0.025 - - - - - - - -
ASTM B240[19] (Ingot)
max 4.3 0.1 0.05 0.004 0.003 0.002 0.075 - - - -
min 3.5 - 0.025 - - - - - - - -
ASTM B86[20] (Cast)
max 4.3 0.25 0.05 0.005 0.004 0.003 0.1 - - - -
min 3.8 - 0.035 - - - - - - - -
EN1774[21] (Ingot)
max 4.2 0.03 0.06 0.003 0.003 0.001 0.02 0.001 0.02 - -
min 3.7 - 0.025 - - - - - - - -
EN12844[22] (Cast)
max 4.3 0.1 0.06 0.005 0.005 0.002 0.05 0.02 0.03 - -
min 3.9 - 0.03 - - - - - - - -
JIS H2201[14] (Ingot)
max 4.3 0.03 0.06 0.003 0.002 0.001 0.075 - - - -
min 3.5 - 0.02 - - - - - - - -
JIS H5301[15] (Cast)
max 4.3 0.25 0.06 0.005 0.004 0.003 0.01 - - - -
min 3.9 - 0.04 - - - - - - - -
AS1881[24]
max 4.3 0.03 0.06 0.003 0.003 0.001 0.05 - 0.001 0.0005 0.001
min 3.9 - 0.03 - - - - - - - -
GB8738-88[12]
max 4.3 0.1 0.06 0.004 0.003 0.0015 0.035 - - - -
†
Impurity
 Zamak 3 properties[4]
Property Metric value English value
Mechanical properties
Ultimate tensile strength 268 MPa 38,900 psi
Yield strength (0.2% offset) 208 MPa 30,200 psi
Impact strength 46 J (56 J aged) 34 ft-lbf (41 ft-lbf aged)
Elongation at F max 3%
Elongation at fracture 6.3% (16% aged)
Shear strength 214 MPa 31,000 psi
Compressive yield strength 414 MPa 60,000 psi
8
Fatigue strength (reverse bending 5x10 cycles) 48 MPa 7,000 psi
Hardness 97 Brinell
Modulus of elasticity 96 GPa 14,000,000 psi
Physical properties
Solidification range (melting range) 381—387 °C 718—729 °F
3
Density 6.7 g/cm 0.24 lb/in3
Coefficient of thermal expansion 27.4 µm/m-°C 15.2 µin/in-°F
Thermal conductivity 113 W/mK 784 BTU-in/hr-ft2-°F
Electrical resistivity 6.37 µΩ-cm at 20 °C 2.51 µΩ-in at 68 °F
Latent heat (heat of fusion) 110 J/g 4.7x10-5 BTU/lb
Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F
Coefficient of friction 0.07

Zamak 5 has the same composition as zamak 3 with the addition of 1% copper in order to increase
strength (by approximately 10%[17]), hardness and corrosive resistance, but reduces ductility.[29] It also has
less dimensional accuracy.[29] Zamak 5 is more commonly used in Europe.[2]
Zamak 5 composition per standard
Alloying elements Impurities
Standard Limit Al Cu Mg Pb Cd Sn Fe Ni Si In Tl
min 3.9 0.75 0.03 - - - - - - - -
ASTM B240[19] (Ingot)
max 4.3 1.25 0.06 0.004 0.003 0.002 0.075 - - - -
min 3.5 0.75 0.03 - - - - - - - -
ASTM B86[20] (Cast)
max 4.3 1.25 0.06 0.005 0.004 0.003 0.1 - - - -
min 3.8 0.7 0.035 - - - - - - - -
EN1774[21] (Ingot)
max 4.2 1.1 0.06 0.003 0.003 0.001 0.02 0.001 0.02 - -
min 3.7 0.7 0.025 - - - - - - - -
EN12844[22] (Cast)
max 4.3 1.2 0.06 0.005 0.005 0.002 0.05 0.02 0.03 - -
min 3.9 0.75 0.03 - - - - - - - -
JIS H2201[14] (Ingot)
max 4.3 1.25 0.06 0.003 0.002 0.001 0.075 - - - -
min 3.5 0.75 0.02 - - - - - - - -
JIS H5301[15] (Cast)
max 4.3 1.25 0.06 0.005 0.004 0.003 0.01 - - - -
min 3.9 0.75 0.04 - - - - - - - -
AS1881[24]
max 4.3 1.25 0.06 0.003 0.003 0.001 0.05 - 0.001 0.0005 0.001
min 3.9 0.7 0.03 - - - - - - - -
GB8738-88[12]
max 4.3 1.1 0.06 0.004 0.003 0.0015 0.035 - - - -
 Zamak 5 properties[29]
Property Metric value English value
Mechanical properties
Ultimate tensile strength 331 MPa (270 MPa aged) 48,000 psi (39,000 psi aged)
Yield strength (0.2% offset) 295 MPa 43,000 psi
Impact strength 52 J (56 J aged) 38 ft-lbf (41 ft-lbf aged)
Elongation at F max 2%
Elongation at fracture 3.6% (13% aged)
Shear strength 262 MPa 38,000 psi
Compressive yield strength 600 MPa 87,000 psi
8
Fatigue strength (reverse bending 5x10 cycles) 57 MPa 8,300 psi
Hardness 114 Brinell
Modulus of elasticity 96 GPa 14,000,000 psi
Physical properties
Solidification range (melting range) 380—386 °C 716—727 °F
3
Density 6.7 kg/dm 0.24 lb/in3
Coefficient of thermal expansion 27.4 µm/m-°C 15.2 µin/in-°F
Thermal conductivity 109 W/mK 756 BTU-in/hr-ft2-°F
Electrical resistivity 6.54 µΩ-cm at 20 °C 2.57 µΩ-in at 68 °F
Latent heat (heat of fusion) 110 J/g 4.7x10-5 BTU/lb
Specific heat capacity 419 J/kg-°C 0.100 BTU/lb-°F
Coefficient of friction 0.08