EZAC
Material Introduction
EZAC is an engineered ultra-high-performance zinc alloy designed for advanced zinc die casting applications requiring exceptional strength, impact resistance, wear resistance, and prolonged durability. As an improved generation of Zn-Al-Cu-Mg alloys, EZAC delivers mechanical properties significantly beyond traditional Zamak series alloys, offering tensile strength approaching 400 MPa, superior creep resistance, and greatly enhanced hardness. These characteristics make EZAC ideal for structural, load-bearing, and long-service components used in power tools, locking systems, automotive hardware, robotics, industrial mechanisms, and other environments where conventional Zamak alloys may experience premature wear or deformation.
EZAC also maintains excellent castability and dimensional stability when processed using high-pressure metal casting systems. With optimized alloy cleanliness and specialty grain-refinement additives, EZAC consistently produces smooth surfaces, well-defined edges, and high precision repeatability. Combined with Neway’s advanced tool and die making capabilities, it enables cost-effective manufacturing of mission-critical components that must simultaneously offer strength, toughness, and premium finishing performance.
Alternative Material Options
If EZAC’s ultra-high strength is not required, cost-optimized options such as Zamak 3 or Zamak 5 provide balanced performance for general applications. For designs requiring higher ductility, Zamak 7 offers improved fluidity and lower impurity formation. When extremely high wear resistance or hardness is required, ZL0430 (ZnAl4Cu3) is a suitable alternative for high strength. For lightweight structural designs or heat-management components, aluminum die-casting alloys like A380 or ADC12 may be preferred. Premium appearance and corrosion resistance requirements may also lead to the use of copper-based alloys, such as Brass 380 or wider copper-brass alloys, for luxury hardware and decorative components.
International Equivalent / Comparable Grade
Country/Region | Equivalent / Comparable Grade | Specific Commercial Brands | Notes |
USA | EZAC (Advanced ZA Series) | Eastern Alloy EZAC, Dynacast EZAC | Optimized Zn-Al-Cu-Mg alloy with extremely high strength. |
Europe (EN) | Enhanced ZnAl4-Mg-Cu Class (non-standard) | European proprietary Zn-Al-Mg performance alloys | No exact EN equivalent; most similar to ZL0430-type alloys with additives. |
China (GB/T) | ZnAl4Cu3-Mg Modified (proprietary) | Custom Zn-Al-Cu-Mg foundry formulations | Used in applications requiring wear resistance and high load capacity. |
Japan (JIS) | No direct ADC equivalent | Specialty Zn-Mg-Cu high-strength grades | Requires proprietary casting alloys for similar performance. |
ISO | Zn-Al-Cu-Mg Enhanced | Special ISO-certified Zn-Mg alloys | Aligned with high-strength zinc casting materials for demanding industries. |
Design Purpose
EZAC was developed specifically to overcome the limitations of Zamak-series alloys in high-load, high-wear, and long-lifecycle applications. Traditional zinc alloys may deform under sustained loads, exhibit creep at moderate temperatures, or wear prematurely in mechanical assemblies. EZAC’s formulation—characterized by elevated aluminum, controlled copper, and magnesium strengthening—provides a fine, refined microstructure that improves strength, hardness, thermal stability, and resistance to fatigue. The alloy’s intent is to provide a zinc-based solution that bridges the performance gap between standard Zamak alloys and much more expensive copper-based or steel components, enabling compact designs with superior reliability, extended service life, and reduced need for additional reinforcements or oversized cross-sections.
Chemical Composition
Element | Zinc (Zn) | Aluminum (Al) | Copper (Cu) | Magnesium (Mg) | Iron (Fe) | Lead (Pb) | Cadmium (Cd) | Tin (Sn) |
Composition (%) | Balance | ~4.0 | ~2.5 | 0.04–0.06 | ≤0.003 | ≤0.003 | ≤0.001 | ≤0.001 |
Physical Properties
Property | Density | Melting Range | Thermal Conductivity | Thermal Expansion |
Value | ~6.7–6.8 g/cm³ | ~381–390°C | ~100–110 W/m·K | ~27–29 µm/m·°C |
Mechanical Properties
Property | Tensile Strength | Yield Strength | Elongation | Hardness | Creep Resistance |
Value | ~380–400 MPa | ~300 MPa | ~3–5% | ~130–140 HB | Significantly higher than Zamak alloys |
Key Material Characteristics
Ultra-high tensile strength approaching 400 MPa—one of the strongest zinc die-casting alloys.
Greatly improved creep resistance for sustained load applications.
Higher hardness than Zamak 3, 5, or 7, suitable for wear-intensive mechanisms.
Refined microstructure reduces porosity and improves repeatability in die casting.
Excellent dimensional stability over long service duration.
Superior fatigue resistance suitable for cyclic loading components.
Good castability with precise edges and fine surface detail.
Compatible with plating, powder coating, and decorative finishing processes.
Improved thermal stability for power tools and industrial assemblies.
Ideal for replacing steel, brass, or bronze in certain load-bearing designs.
Manufacturability And Post Process
Zinc die casting: EZAC performs best in hot-chamber die casting for complex, precision components.
Insert casting: Works well with steel and brass 360 inserts to improve wear zones.
Secondary machining: Requires sharper tools due to higher hardness; tolerances of ±0.02–0.05 mm achievable.
Drilling and tapping: Use controlled torque due to high hardness; thread forming is preferred.
Tumbling and deburring: Effective for EZAC’s harder surface, smoothing edges without deformation.
Painting, powder coating, and plating: Excellent adhesion when properly pre-treated.
Sand blasting: Common for cosmetic surface preparation.
Suitable Surface Treatment
Powder coating: Highly durable for heavy-use assemblies.
Liquid painting: Suitable for consumer-grade appearance.
Electroplating: Chrome, nickel, and multi-layer decorative plating supported.
Bead blasting: Creates uniform matte surfaces.
Chemical conversion coatings: Improves corrosion resistance and paint adhesion.
E-coating: Uniform protection for complex geometries.
Laser marking: Suitable for traceability and aesthetic branding.
Common Industries and Applications
Power tools: High-load levers, gears, triggers, and structural brackets.
Locking systems & security hardware: Cams, cylinders, sliders, latches, anti-tamper hardware.
Automotive interior & functional components: Brackets, mechanical linkages, reinforced housings.
Robotics and automation: Wear-resistant gears, linkages, and actuating elements.
Industrial machinery: Stress-bearing small components requiring long-life performance.
Consumer goods: Durable mechanisms for appliances, wear-prone fittings, and premium hardware.
When to Choose This Material
When maximum strength is required: EZAC exceeds all Zamak alloys in strength and hardness.
For heavy-load mechanisms: Excellent for gears, levers, sliders, cams, and transmission elements.
When long-life performance matters: Extremely low creep and fatigue damage under repeated stress.
For compact or miniaturized designs: High strength allows thinner walls and smaller geometries.
For wear-intensive components: Hardness ~130–140 HB provides superior abrasion resistance.
For upgraded Zamak 5 / ZL0430 performance: A premium alternative for demanding assemblies.
For replacing heavier metals: Can replace brass or bronze in many mechanical designs.
For industrial and power-tool applications: Proven performance in sustained mechanical load environments.
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