When it comes to choosing the right metal for your project, understanding the differences between Zamak, Aluminum, and Brass is essential. Each of these materials has unique properties, chemical compositions, and applications that make them suitable for specific purposes. In this article, we’ll break down their key characteristics, advantages, and ideal use cases to help you find out the differences between Zamak, aluminium and brass.
What is Zamak?
Zamak is a family of zinc-based alloys made primarily from zinc with small amounts of aluminum, magnesium, and copper, widely used in die casting for its excellent strength, dimensional stability, and surface finishing properties. The name comes from the German words for its components: Zink, Aluminium, MAgnesium, and Kupfer (copper). Zamak alloys are valued for being easy to cast with fine detail, resistant to corrosion, and suitable for plating or painting, making them common in automotive parts, household hardware, toys, and precision components where durability and appearance are equally important.
Zamak Advantages
Excellent castability – flows well in die casting, allowing thin walls and intricate shapes.
High dimensional accuracy – produces precise parts with minimal machining.
Good strength and hardness compared to pure zinc.
Corrosion resistance – performs well in many environments.
Smooth surface finish – ideal for plating, painting, and polishing.
Cost-effective – cheaper than copper- or aluminum-based alloys.
Recyclable – can be reused without major property loss.
Zamak Disadvantages
Lower melting point than aluminum alloys (limits high-temperature applications).
Brittleness compared to steel or brass, especially under impact.
Creep issues – can deform under long-term stress at moderate temperatures.
Not ideal for structural or load-bearing parts requiring very high strength.
Zamak Applications
Automotive parts: carburetors, door handles, housings.
Consumer goods: zippers, toys, locks, kitchen appliances.
Hardware: hinges, handles, fittings, plumbing accessories.
Electronics: connectors, casings, small housings.
Decorative items: lighting fixtures, furniture parts, jewelry bases.
Zamak Compositions
(Approximate percentages vary by grade, e.g., Zamak 2, Zamak 3, Zamak 5, Zamak 7)
Zinc (Zn): 94–96%
Aluminum (Al): 3.5–4.3%
Copper (Cu): 0–3% (higher Cu = more strength, less ductility)
Magnesium (Mg): ~0.03%
Trace elements (Iron, Nickel, Tin): <0.1%
Examples:
Zamak 3: Standard alloy (96% Zn, 4% Al).
Zamak 5: Stronger, with ~1% Cu added.
Zamak 7: Improved fluidity, low magnesium.
Zamak 2: Highest strength, ~3% Cu, but less ductile.
Zamak Price
Zamak is relatively affordable compared to aluminum, brass, and copper alloys. As of 2025, bulk Zamak alloy ingots typically cost around $2,200 – $2,800 per metric ton, depending on grade, region, and market zinc prices. Since zinc is the main component, zinc price fluctuations directly impact Zamak pricing.
What is Aluminium?
Aluminium is a lightweight, silvery-white metal known for its low density, high strength-to-weight ratio, corrosion resistance, and excellent recyclability, making it one of the most widely used materials in the world. As the third most abundant element in the Earth’s crust, it is refined from bauxite ore through the Bayer and Hall-Héroult processes. Aluminium’s properties—such as being non-magnetic, a good conductor of heat and electricity, and easily formable—make it essential in industries ranging from aerospace, automotive, and construction to packaging, electronics, and consumer goods.
Aluminum Advantages
Lightweight – about one-third the density of steel or copper.
Excellent corrosion resistance due to natural oxide layer.
Good thermal and electrical conductivity.
Easily workable – supports casting, forging, extrusion, and rolling.
Recyclable without loss of quality.
Non-toxic – safe for food and medical use.
Can be surface treated (anodizing, painting, polishing) for aesthetics.
Aluminum Disadvantages
Lower strength than steel or brass (though alloys improve this).
Soft and ductile – can wear or deform under heavy load.
Fatigue and creep issues under long-term stress at high temperatures.
Welding can be difficult compared to steel.
Higher cost than zinc-based alloys (like Zamak).
Aluminum Applications
Transportation: automotive, aerospace, ships, trains.
Construction: window frames, roofing, panels, structural components.
Electrical: power lines, conductors, casings.
Consumer goods: laptops, phones, kitchenware, packaging (cans, foils).
Industrial: machinery parts, heat exchangers, piping.
Medical: surgical tools, prosthetics, implants.
Aluminum Compositions
Pure Aluminum (Al): ~99% Al (soft, ductile, corrosion resistant).
Alloying Elements (vary by grade):
Silicon (Si): improves strength & castability.
Magnesium (Mg): adds corrosion resistance & strength.
Copper (Cu): increases hardness & machinability, reduces corrosion resistance.
Manganese (Mn), Zinc (Zn), Iron (Fe): added in small amounts for strength and stability.
Example Alloys:
1000 Series: ≥99% Al, high corrosion resistance, low strength.
2000 Series: Al-Cu alloys, very strong, used in aerospace.
5000 Series: Al-Mg alloys, corrosion resistant, used in marine.
6000 Series: Al-Mg-Si alloys, versatile, strong, used in construction and automotive.
7000 Series: Al-Zn alloys, ultra-strong, used in aerospace.
Aluminum Price
More expensive than Zamak, cheaper than brass or copper. As of 2025: around $2,400 – $3,000 per metric ton (depending on alloy, purity, and market conditions). Price is influenced by global energy costs (aluminum smelting is energy-intensive).
What is Brass?
Brass is an alloy of copper and zinc, prized for its bright gold-like appearance, corrosion resistance, and excellent machinability. By adjusting the copper-to-zinc ratio, manufacturers can produce different types of brass with varying levels of strength, ductility, and acoustic properties. Known for being easy to cast, forge, and machine, brass is widely used in plumbing fittings, musical instruments, decorative hardware, electrical components, and marine applications. Its combination of durability, aesthetic appeal, and resistance to tarnishing makes it one of the most versatile and historically important copper alloys.
Brass Advantages
Excellent corrosion resistance, especially in water and mild environments.
Attractive golden appearance, suitable for decorative items.
Good machinability – easy to cut, drill, and form.
High strength and hardness compared to pure copper.
Good wear resistance – ideal for gears, bearings, and fittings.
Non-magnetic – useful in electronic and precision instruments.
Recyclable – can be reused with minimal property loss.
Brass Disadvantages
More expensive than aluminum and zinc alloys (like Zamak).
Heavier than aluminum (higher density).
Prone to dezincification (loss of zinc in some environments, weakening the alloy).
Not suitable for very high-temperature applications compared to steel.
Lead-containing brasses can raise environmental and health concerns.
Brass Applications
Plumbing & fittings: valves, taps, pipe connectors.
Electrical: terminals, switches, connectors.
Decorative: jewelry, ornaments, musical instruments (trumpets, saxophones).
Engineering: gears, bearings, locks, fasteners.
Marine: ship fittings, propellers, due to corrosion resistance.
Architecture: railings, door handles, decorative panels.
Brass Compositions
Copper (Cu): ~55–95%
Zinc (Zn): ~5–45%
Other elements (optional, depending on grade):
Lead (Pb): improves machinability.
Tin (Sn): increases corrosion resistance (naval brass).
Aluminum (Al), Manganese (Mn), Nickel (Ni): added in small amounts to enhance strength or durability.
Examples:
Yellow Brass: ~67% Cu, 33% Zn (common for hardware, plumbing).
Red Brass: ~85% Cu, 15% Zn (stronger, corrosion resistant).
Naval Brass: Cu, Zn, + ~1% Sn (marine applications).
Free-Cutting Brass: Cu, Zn, + ~2–3% Pb (excellent machinability).
Brass Price
More expensive than aluminum and Zamak, but cheaper than pure copper. As of 2025: typically $4,500 – $6,000 per metric ton, depending on composition and copper market prices. Price mainly influenced by the global copper price, since copper is the dominant component.
Zamak vs Aluminum, What’s the Difference?
| Category | Zamak | Aluminum |
|---|---|---|
| Material Type | Zinc-based alloy (Zn + Al + Cu + Mg) | Lightweight metal (Al + alloying elements) |
| Chemical Composition | Zn: 94–96%, Al: 3.5–4.3%, Cu: 0–3%, Mg: ~0.03% | Al: 85–99% + Si, Mg, Cu, Mn, Zn (varies by series) |
| Melting Point | ~380 °C | ~660 °C |
| Rust/Corrosion | Does not rust; can corrode; often plated | Does not rust; forms protective oxide layer |
| Density | ~6.6 g/cm³ (heavier) | ~2.7 g/cm³ (lightweight) |
| Strength | Moderate strength, high hardness | Stronger (esp. alloys), structural use |
| Ductility | More brittle, less formable | More ductile, easy to form/extrude |
| Thermal/Electrical Conductivity | Moderate | Excellent |
| Wear Resistance | Good (gears, locks, fittings) | Softer, needs alloying/treatment for wear resistance |
| Applications | Small precision castings, hardware, automotive, decorative parts | Transportation, construction, electronics, packaging, aerospace |
| Price (2025) | $2,200 – $2,800 / metric ton | $2,40 |
Zamak vs Aluminum, What Should You Choose？
Choosing between Zamak and Aluminum depends on your priorities: if you need complex, precise, and cost-effective die-cast parts with good wear resistance (like locks, fittings, or decorative hardware), Zamak is the better choice thanks to its low melting point and casting efficiency. However, if your project demands lightweight strength, corrosion resistance, and structural reliability (like in aerospace, automotive, construction, or electronics), Aluminum is the superior option. In short, Zamak suits small durable components, while Aluminum excels in structural and weight-sensitive applications.
Zamak vs Brass, What’s the Difference?
| Category | Zamak | Brass |
|---|---|---|
| Material Type | Zinc-based alloy (Zn + Al + Cu + Mg) | Copper-zinc alloy |
| Chemical Composition | Zn: 94–96%, Al: 3.5–4.3%, Cu: 0–3%, Mg: ~0.03% | Cu: 55–90%, Zn: 10–45%, small amounts of Pb, Sn, Fe (depending on type) |
| Melting Point | ~380 °C | ~900–940 °C |
| Rust/Corrosion | Does not rust; can corrode; often plated | Does not rust; good corrosion resistance, especially in dry environments |
| Density | ~6.6 g/cm³ (heavier than aluminum) | ~8.4–8.7 g/cm³ (denser) |
| Strength | Moderate strength, high hardness | High strength, tougher than Zamak |
| Ductility | More brittle, less formable | Highly ductile, easy to machine and form |
| Thermal/Electrical Conductivity | Moderate | Excellent (better than Zamak) |
| Wear Resistance | Good (gears, locks, fittings) | Excellent |
| Applications | Small precision castings, hardware, automotive, decorative parts | Plumbing, electrical connectors, musical instruments, decorative parts |
| Price (2025) | $2,200 – $2,800 / metric ton | $5,000 – $6,000 / metric ton |
Zamak vs Brass, What Should You Choose？
Choosing between Zamak and Brass depends on your project needs: if you need low-cost, precise, die-cast components like locks, handles, or small automotive and decorative parts, Zamak is the better choice due to its low melting point, ease of casting, and moderate strength. On the other hand, if your priority is strength, ductility, wear resistance, and corrosion resistance for applications such as plumbing, electrical connectors, musical instruments, or high-quality decorative pieces, Brass is the superior option. In short, Zamak excels in affordable, small precision castings, while Brass is ideal for durable, machinable, and high-quality parts.
Aluminium vs Brass, What’s the Difference?
| Category | Aluminum | Brass |
|---|---|---|
| Material Type | Lightweight metal (Al + alloying elements) | Copper-zinc alloy |
| Chemical Composition | Al: 85–99% + Si, Mg, Cu, Mn, Zn (varies by alloy series) | Cu: 55–90%, Zn: 10–45%, small amounts of Pb, Sn, Fe (depending on type) |
| Melting Point | ~660 °C | ~900–940 °C |
| Rust/Corrosion | Does not rust; forms protective oxide layer | Does not rust; good corrosion resistance, especially in dry environments |
| Density | ~2.7 g/cm³ (lightweight) | ~8.4–8.7 g/cm³ (denser) |
| Strength | Strong (especially in alloys); good for structural use | High strength; tougher than aluminum |
| Ductility | More ductile, easy to form/extrude | Highly ductile, easy to machine and form |
| Thermal/Electrical Conductivity | Excellent | Excellent (slightly better electrical conductivity than Zamak, comparable to aluminum) |
| Wear Resistance | Softer, may need alloying or surface treatment | Excellent |
| Applications | Transportation, construction, electronics, packaging, aerospace | Plumbing, electrical connectors, musical instruments, decorative parts |
| Price (2025) | $2,400 – $3,000 / metric ton | $5,000 – $6,000 / metric ton |
Brass vs Aluminum, What Should You Choose？
Choosing between Aluminum and Brass depends on your priorities: if you need lightweight, strong, and corrosion-resistant materials for structural, transportation, aerospace, or electronics applications, Aluminum is the ideal choice due to its low density, good strength-to-weight ratio, and excellent protective oxide layer. However, if your project requires higher density, machinability, wear resistance, and aesthetic appeal—for example in plumbing, electrical connectors, musical instruments, or decorative hardware—Brass is the better option. In short, Aluminum is best for lightweight structural use, while Brass is preferred for durable, precision, and decorative applications.
Whats Stronger Brass or Aluminum?
When comparing strength, brass is generally stronger than aluminum in terms of hardness and tensile strength. Brass, an alloy of copper and zinc, typically has higher compressive and yield strength, making it more resistant to deformation under load. Aluminum, on the other hand, is much lighter and more corrosion-resistant but has lower tensile and yield strength in its pure form. However, certain aluminum alloys (like 7075 or 6061-T6) can approach or even exceed the strength of some brass grades while maintaining a significant weight advantage, which is why aluminum is preferred in applications where lightweight yet strong materials are essential, such as aerospace or automotive components.