What is Zamak & Zamak Properties - Types of Zamak Alloys | Diecasting-mould
What alloy is the most widely used material in the zinc die casting process? Zamak is a special being of zinc alloy. In this article, we’ll break down what is Zamak and how it’s named, the properties and its alloying elements, uses, and types.
What is Zamak? - The Name Meaning of Zamak
ZAMAK, also known as Zamac, formerly represented as MAZAK, is a family of alloys with a base metal of zinc and alloying elements of aluminum, magnesium, and copper. ZAMAK is distinguished from other zinc alloys by its constant 4% aluminum content, zinc by itself doesn’t have enough mechanical properties to hold its shape, but at the same time, it has very good corrosion resistance, so that’s why we need aluminum in our alloy. With capital letters here in ZAMAK, Z stands for zinc, A stands for aluminum, MA a stands for magnesium, K stands for copper, which comes from the German language, the German names for the metals of which the alloys are composed: Zink (zinc), Aluminium, Magnesium, and Kupfer (copper). In the alloy, aluminum is used, it’s 4% and we have other relative elements magnesium and copper.
What is Zamak used for? The first one and very important one is automotive parts, more common uses are blenders, mirror frames, plumbing fittings, zipper, bathroom fixtures, handles, locks, tooling, fishing reels, ceiling fans, etc. Zamak is a popular material in die casting services due to its resistance to shocks, wear, and corrosion, high accuracy, inexpensive prices, safety, and more benefits.
Properties of Zamak Explained
How do these alloying elements affect the properties of Zamak? When talking about aluminum, if we have less than 3.5% aluminum in our alloy, less than 2.5%, the strength goes down, if we increase the amount of aluminum such as more than 4.5%, the tensile strength goes down so that means hardness increases, so in metallurgy, that means it becomes a breathable material so that’s why we keep it at the level. We need aluminium to increase the strength, it helps zinc to hold these shapes increase strength and fluidity. Secondly, magnesium is used to remove unwanted elements such as tin or lead, some elements like that to remove impurities or unwanted things. Lastly, copper is used to increasing hardness. In a word, we need an alloy other than zinc because it must be strong enough to hold its shape or it must be fluid because it is often used in die casting, this is a very important property. Zamak can be electroplated, wet painted, and chromate conversion coated well.
Types of Zamak Alloys
The most common Zamak alloy is Zamak 3. Besides that, Zamak 2, Zamak 5, and Zamak 7 are also commercially used. These alloys are most commonly die cast.
– Zamak 2: the composition is the same as that of Zamak 3, adding 3% copper in order to increase strength by 20%, which also increases the price. Zamak 2 has the highest tensile strength, hardness and creep performance out of all the Zamak alloys. Over time it retains its strength and hardness better than the other alloys; however, it becomes more brittle, shrinks, and is less elastic. Zamak 2 is easily cast, coated and machined.
– Zamak 3: the standard for the Zamak series, has the base composition for the Zamak alloys (96% zinc, 4% aluminum). It has excellent castability and long-term dimensional stability. Grade Zamak 3 also offers great finishing characteristics for plating and painting. The most commonly used alloy in North American zinc die casting.
– Zamak 5: the same composition as Zamak 3, adding 1% copper to increase strength by about 10%, hardness and corrosion resistance, but reduces ductility. Less dimensional accuracy than Zamak 3.
– Zamak 7: less magnesium content than Zamak 3 to increase fluidity and ductility, which is especially useful when producing thin-wall castings. In order to reduce inter-granular corrosion, a small amount of nickel is added and impurities are more strictly controlled.-
What is Zamak Price?
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Bulk Pricing (Wholesale)
Zamak 3 Alloy: Approximately $2,800–$2,850 per ton (USD), with a minimum order of 25 tons.
Zamak 5 Alloy: Approximately $1,150–$1,250 per ton (USD), with a minimum order of 25 tons.
Small-Scale Purchases (Individual Ingots)
Zamak 3 Ingot: Around $21.99 per 4 lb ingot.
Zamak 2 Ingot: Approximately $21.99 per 4 lb ingot.
Zamak 5 Ingot: Also about $21.99 per 4 lb ingot.
Market Trends
The price of Zamak is influenced by the cost of its primary components—zinc, aluminum, and copper. As of August 18, 2025, the zinc spot price is approximately $3,777 per ton (USD). Zamak prices have historically been higher than aluminum prices, with a difference of over $400 per ton in recent years.
Zamak Alloy Compositions
Zinc (Zn): ~95%
Aluminum (Al): ~4%
Magnesium (Mg): ~0.03%
Copper (Cu): ~0.75%
Different grades (Zamak 2, 3, 5, 7, etc.) vary slightly in copper and magnesium content to adjust mechanical properties.
Zamak 3
Zinc (Zn): ~96%
Aluminum (Al): ~4%
Magnesium (Mg): ~0.03–0.06%
Copper (Cu): ≤0.03%
Zamak 5
Zinc (Zn): ~95%
Aluminum (Al): ~4%
Magnesium (Mg): ~0.03–0.06%
Copper (Cu): 1%
Applications of Zamak Material
Automotive parts (car door handles, interior fittings).
Hardware (locks, hinges, knobs).
Electronics housings and connectors.
Toys, watches, and decorative items.
Industrial machine components.
What's Zamak Melting Point?
Zamak has a relatively low melting point compared to steel or aluminum alloys, which is one reason it’s widely used in die casting.
Typical melting range: 380–390 °C (716–734 °F)
Solidification point: Starts to solidify slightly below 380 °C, depending on the exact Zamak grade.
Note on grades:
Zamak 2, 3, 5: ~380 °C
Zamak 7: slightly lower (~375 °C) due to altered copper content
This low melting point makes Zamak energy-efficient for casting, allows for thin-walled, detailed parts, and makes it easy to plate or finish after casting.
How's Zamak Corrosion?
Zamak corrosion refers to how zinc-based Zamak alloys degrade when exposed to moisture, chemicals, or outdoor environments. While Zamak has some natural corrosion resistance due to its zinc content, it is not as corrosion-resistant as stainless steel or properly galvanized steel.
Corrosion Behavior
Zinc base: The zinc in Zamak naturally forms a thin protective oxide layer (patina) that slows further corrosion.
Environmental sensitivity:
Indoor, dry environments: Minimal corrosion, can last decades.
Outdoor exposure: Susceptible to oxidation, especially in humid, acidic, or salty conditions.
Coastal areas or industrial pollution: Chlorides and sulfates accelerate corrosion.
Factors Affecting Corrosion
Alloy grade
Zamak 5 (with higher copper) has slightly better corrosion resistance than Zamak 3.
Zamak 2 is less corrosion-resistant due to lower zinc content.
Surface finish
Chrome, nickel, or powder coatings significantly improve corrosion resistance.
Painting or sealing also helps in outdoor use.
Mechanical stress
Scratches or wear can expose the underlying alloy, speeding up corrosion.
Will Zamak Rust?
Rust specifically refers to the reddish-brown iron oxide that forms when iron or steel corrodes. Zamak is a zinc-based alloy (with aluminum, magnesium, and copper), so it cannot form rust.
What happens to Zamak outdoors or in moisture
It can corrode, but this appears as a dull gray or whitish patina rather than red rust. The zinc in Zamak forms a protective layer of zinc oxide or zinc carbonate, which slows further corrosion. In harsh environments (saltwater, acidic conditions), Zamak may pimple, pit, or develop surface powdery corrosion, but not true rust.