What are the differences between Zamak 3, 5, and 7 for automotive handles?

What Are the Differences Between Zamak 3, 5, and 7 for Automotive Handles?

Overview of Zamak Alloys in Automotive Applications

Zamak alloys are zinc-based materials widely used in die casting for automotive components due to their excellent strength, dimensional stability, and surface finish characteristics. For exterior and interior automotive handles, Zamak 3, 5, and 7 are commonly selected. Each grade offers unique performance features that influence durability, corrosion resistance, and manufacturability.

Zamak 3: Standard Alloy for Balanced Performance

Zamak 3 is the most commonly used Zamak alloy, offering a well-balanced combination of mechanical strength, dimensional accuracy, and castability.

• Composition: Zinc with ~4% aluminum

• Tensile Strength: ~283 MPa

• Elongation: ~10%

• Excellent dimensional stability and surface finish

• Best suited for non-structural or interior handles requiring consistent aesthetics

Zamak 3 is ideal when cosmetic appearance and corrosion protection via painting or plating are critical.

Zamak 5: Enhanced Strength for Functional Handles

Zamak 5 includes a small amount of copper (~1%) in addition to aluminum, increasing mechanical strength and wear resistance.

• Composition: Zinc, ~4% aluminum, ~1% copper

• Tensile Strength: ~331 MPa

• Elongation: ~7%

• Greater hardness and better performance under mechanical stress

• Suitable for exterior or structural handles that undergo frequent use or load

Zamak 5 is recommended when additional rigidity or resistance to mechanical wear is needed in handle mechanisms.

Zamak 7: High-Fluidity Alloy for Fine Detail

Zamak 7 is a modified version of Zamak 3 with improved fluidity and surface finish.

• Composition: Similar to Zamak 3 with reduced magnesium and iron

• Tensile Strength: ~276 MPa

• Elongation: ~13%

• Exceptional casting accuracy for fine-featured components

• Preferred for intricate or thin-walled handle designs where detail and finishing are essential

Zamak 7 is often chosen for design-heavy automotive interiors or handles with embedded logos or precise texturing.

Comparison Table for Automotive Handle Use

Neway’s Automotive Zinc Casting Capabilities

Neway supports automotive handle production through:

• Precision zinc die casting with Zamak 3, 5, and 7

• Functional tool and die making for detailed and dimensionally stable parts

• Corrosion-resistant surface finishing, including powder coating and painting

• Rapid prototyping for testing ergonomic or structural handle designs