Zamak 9

Alternative Material Options

If Zamak 9’s performance profile does not perfectly fit a specific project, Neway can recommend several alternative alloys. For highly economical, general-purpose parts with excellent castability, Zamak 3 remains the global standard. When slightly higher strength is required without a significant cost increase, Zamak 5 offers improved mechanical properties and broad industrial applications. For very thin-wall or highly ductile applications, Zamak 7 is preferred due to its superior fluidity and elongation. In cases where extreme strength, wear resistance, or bearing performance is critical, copper-rich alloys such as Zamak 2 or Russian TSAM series alloys can be considered. For projects driven by premium aesthetics or thermal performance, aluminum alloys like A380 or A383/ADC12 and copper-based alloys such as Brass 380 or other copper-brass alloys provide additional design flexibility.

International Equivalent / Comparable Grade

Design Purpose

Zamak 9 was developed to provide a zinc die-casting alloy with superior mechanical strength, hardness, and corrosion resistance compared with traditional Zamak 3 and Zamak 5, while still leveraging zinc’s excellent castability and finishing characteristics. By increasing the aluminum and copper content, Zamak 9 achieves improved performance in applications exposed to outdoor conditions, light marine environments, or continuous mechanical contact and sliding wear. Typical target components include precision lock parts, marine-adjacent hardware, communication equipment housings, drive components, and small mechanisms where dimensional repeatability and surface quality are critical. Paired with Neway’s metal casting expertise and robust process control, Zamak 9 enables design engineers to reduce section thickness, integrate functions, and improve product lifespan without resorting to heavier or more expensive copper alloys.

Chemical Composition

Physical Properties

Mechanical Properties

Key Material Characteristics

• Higher aluminum and copper content delivers increased strength and hardness compared with standard Zamak alloys.

• Improved corrosion resistance, making it suitable for outdoor or mildly marine environments when properly coated.

• Excellent castability for high-pressure Zamak 9 die casting of complex, medium- to thin-walled components.

• Stable dimensional performance across large batches, ideal for precision mechanisms and interlocking parts.

• Compatible with a wide range of post-processing for die castings, including machining, finishing, and coating.

• Good bearing and sliding properties for cams, followers, and small guide elements.

• Excellent surface quality, enabling decorative finishes and premium brand aesthetics.

• Relatively low casting temperature, which reduces thermal stress on dies and cores and extends tool life.

• Suitable for integration into multi-component assemblies, including over-molded or insert-cast hardware.

• Supports design-driven part consolidation that replaces multiple machined or stamped parts with a single casting.

Manufacturability And Post Process

• High-pressure zinc die casting: Primary process for Zamak 9, combining fine feature replication with high throughput.

• Sand casting: Applicable for larger fixtures, low-volume machinery components, or development parts using the same alloy family.

• Gravity die casting: Offers sound sections for moderately thick components requiring strong, defect-minimized structures.

• Insert casting: Steel pins, shafts, or bushings can be cast directly into Zamak 9 to simplify assembling operations.

• Post machining: Boring, milling, and turning operations provide tight tolerance fits (typical ±0.02–0.05 mm) for functional features.

• Drilling and tapping: Zamak 9 accepts threaded holes and fine-pitch fasteners when tool geometry and cutting speeds are optimized.

• Tumbling and vibratory finishing efficiently remove burrs and smooth edges prior to coating or assembly.

• Integrated assemblies: Neway can combine Zamak 9 cast parts with aluminum, steel, or plastic components in dedicated assembly cells.

Suitable Surface Treatment

• Powder coating: Provides durable, chip-resistant protection with film thickness typically 60–100 μm for outdoor and industrial hardware.

• Liquid painting: Offers flexible color matching and high-gloss or matte finishes for branded consumer products.

• Electroplating (nickel, chrome, etc.): Delivers premium metallic appearance and additional wear and corrosion resistance.

• E-coating: Ensures uniform coverage on complex geometries and internal cavities with thin, corrosion-resistant films.

• Chromate conversion: Forms a thin, conductive, corrosion-resistant layer commonly used as a base for additional coatings.

• Sand-blasting or bead blasting: Creates consistent textures, masking minor surface variations and preparing parts for coating.

• Comprehensive post process solutions: Neway integrates mechanical finishing, coating, and quality control to deliver ready-to-use Zamak 9 components.

Common Industries and Applications

• Locking systems: Cylinders, cams, and accessory hardware similar to industrial lock system accessories requiring strength and wear resistance.

• Power tools and equipment: Precision housings, brackets, and structural fittings comparable to power tool hardware projects.

• Consumer and luxury hardware: Decorative caps, knobs, and trim parts, along the lines of perfume bottle caps and premium packaging components.

• Communication and electronics: Connectors, structural brackets, and high-detail housings used in telecom and electronics hardware.

• Industrial machinery: Small levers, clamps, and linkage parts where compact size, strength, and corrosion performance must be balanced.

• Light marine and outdoor products: Hardware and fittings that benefit from enhanced corrosion resistance when paired with robust coatings.

When to Choose This Material

• Elevated strength and hardness: When a project requires higher mechanical performance than Zamak 3 or Zamak 5, but without switching to heavier brass or steel.

• Outdoor or mildly marine environments: Where corrosion resistance and robust coating systems are critical to product life.

• Compact, high-load mechanisms: For cams, locking parts, and drive elements where dimensional stability and wear resistance are crucial.

• High-precision, high-volume casting: When leveraging Neway’s mass production zinc die casting capabilities for consistent quality across large batches.

• Design optimization and part consolidation: Projects supported by design and engineering services to integrate multiple functions into a single casting.

• Prototyping to production: Programs that start with prototyping and low-volume runs before scaling into low volume manufacturing or full mass production.

• High-value coated or plated components: When visual quality and surface durability must align with brand expectations.

• One-supplier integration: Ideal for customers leveraging Neway’s one-stop service from alloy selection and casting material optimization to finishing and assembly.