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ZL041

High-precision zinc alloy delivering excellent fluidity, stability, and smooth surfaces for complex die-cast applications.

Material Introduction

ZL041 is a high-quality zinc alloy engineered specifically for precision zinc die casting, offering excellent fluidity, remarkable dimensional accuracy, and strong mechanical stability. This alloy is widely selected for complex miniature components, thin-wall housings, and decorative hardware that require both strength and aesthetically pleasing surface capabilities. With its refined chemical composition and low impurity levels, ZL041 provides enhanced casting reliability, reduced porosity, and excellent surface smoothness—ideal for subsequent finishing processes. When utilized with Neway’s advanced tool and die making systems and precision-controlled production lines, ZL041 consistently delivers high repeatability and outstanding performance in high-volume manufacturing of electronic devices, locking mechanisms, consumer products, and detailed ornamental components.

International Names or Representative Grades

Region	Common Name	Representative Grades
USA	Zinc Die-Cast Alloy	Zamak 3, Zamak 5
Japan	JIS Zinc Alloy	ZDC1, ZDC2
Europe	EN Zinc Alloy	ZL0430, ZL041
China	Zinc Alloy	ZL040, ZL041
Consumer Products	Precision Zinc Alloy	Zamak 7, Zamak 9

Alternative Material Options

When specific performance requirements exceed ZL041’s capabilities, several alternatives are available. For applications demanding higher strength and hardness, Zamak 5 provides superior mechanical properties. If cost-effectiveness and broad availability are priorities, Zamak 3 is the most commonly used standard zinc alloy. For ultra-high fluidity or improved ductility in micro-precision parts, Zamak 7 is an excellent substitute. When enhanced corrosion resistance or luxury aesthetics are required, copper-based materials, such as Brass 380 or copper-brass alloys, offer a premium alternative. For lightweight structural advantages, aluminum die-cast alloys such as A380 or A383/ADC12 may be selected, especially where thermal performance and weight reduction are key considerations.

Design Purpose

ZL041 was designed to fulfill the need for highly precise, smooth-surface, and dimensionally stable zinc die-cast components used in consumer electronics, decorative accessories, and compact mechanical systems. Its optimized aluminum and magnesium content improves fluidity, reduces shrinkage defects, and increases resistance to hot cracking during high-pressure casting. The alloy supports detailed geometries, clean edges, and refined textures, making it ideal for components that require immediate use or premium finishing. Its purpose is to enhance manufacturing efficiency while providing durability, visual quality, and excellent compatibility with surface enhancements such as plating and powder coating.

Chemical Composition

Element	Composition (%)
Zinc (Zn)	Balance
Aluminum (Al)	3.8–4.2
Copper (Cu)	0.02–0.25
Magnesium (Mg)	0.03–0.06
Iron (Fe)	≤0.075
Lead/Cadmium/Tin	Trace (<0.003 each)

Physical Properties

Property	Value
Density	~6.6 g/cm³
Melting Range	~381–386°C
Thermal Conductivity	~105 W/m·K
Electrical Conductivity	~27% IACS
Thermal Expansion	27–30 µm/m·°C

Mechanical Properties

Property	Typical Value
Tensile Strength	~300 MPa
Yield Strength	~230 MPa
Elongation	1–2%
Hardness	~95–110 HB
Impact Strength	Moderate

Key Material Characteristics

Excellent fluidity enables fine details and precise production of thin-wall components.
Low impurity content enhances stability, reduces porosity, and improves surface finish.
Outstanding dimensional repeatability for high-volume metal casting applications.
Good room-temperature strength suitable for durable mechanical parts.
Smooth as-cast surfaces are ideal for plating, coating, or decorative finishing.
Reliable casting performance with reduced cracking or soldering during high-pressure die casting.
Compatible with assembling operations for multi-component systems.
Strong corrosion resistance suitable for consumer electronics and interior automotive parts.
Lower melting point reduces energy consumption and cycle time.
Enhanced castability enables intricate components to be manufactured with minimal machining.

Manufacturability in Different Processes

High-pressure zinc die casting: Ideal for intricate shapes utilizing zinc die casting technologies.
CNC machining: Works well with CNC machining for precise secondary features.
Surface preparation: Effective with sand blasting and tumbling to improve texture.
Decorative finishing: Highly suitable for electroplating, enabling premium visual results.
Painting and coating: Compatible with painting and powder coating.
Mold optimization: Performs best with professional die-casting design services.
Post-machining: Achieves tight tolerances using precision post machining.
Assembly integration: Supports high-efficiency assembling workflows.