What Zamak alloys are best suited for electrical connector applications?

What Zamak Alloys Are Best Suited for Electrical Connector Applications?

Requirements for Electrical Connector Components

Electrical connectors require dimensional accuracy, thermal stability, and excellent conductivity where grounding or shielding is involved. For die cast connectors, materials must also provide sufficient mechanical strength, corrosion resistance, and the ability to support post-plating for conductivity enhancement. Zamak alloys are ideal for these applications due to their high castability, surface quality, and compatibility with electroplating.

Recommended Zamak Alloys for Connectors

Zamak 3

Zamak 3 is the most commonly used alloy for electrical connectors. It offers:

• Good electrical conductivity (~27% IACS)

• Excellent dimensional stability

• High fluidity for thin-wall castings

• Ideal for shielding enclosures and terminal housings

Zamak 3 is preferred when a balance of cost, conductivity, and stability is required, especially for connectors with integrated grounding or EMI shielding.

Zamak 2

Zamak 2 includes higher copper content (~3%) for increased hardness and wear resistance:

• Better strength and fatigue resistance than Zamak 3

• Useful for connectors exposed to vibration or mechanical cycling

• Slightly lower ductility and conductivity compared to Zamak 3

It is often selected for connector shells or fasteners where structural support and high dimensional stability are critical.

Zamak 7

Zamak 7 is a high-fluidity version of Zamak 3, offering:

• Improved surface finish and finer detail

• Better casting of intricate connector housings or compact multi-pin layouts

• Suitable for miniaturized components requiring high precision

Zamak 7 is ideal for connectors with detailed cavities, snap-fit features, or ultra-fine wall sections.

Key Advantages of Using Zamak in Connectors

• Shielding effectiveness: Conductive die cast housings protect sensitive electronics from EMI/RFI

• Electroplating compatibility: Easily accepts copper, nickel, or tin coatings to improve surface conductivity

• High cast precision: Supports tight-tolerance interfaces between connector halves

• Thermal conductivity: Assists in passive heat dissipation for high-power terminals

Neway supports post-casting processes like CNC machining, electroplating, and assembly for complete connector solutions.

Neway’s Zamak Connector Manufacturing Capabilities

Neway manufactures precision zinc castings for electrical systems through:

• High-accuracy zinc die casting using Zamak 3, 2, and 7

• Custom tool and die making for complex pin and shell geometries

• Advanced post-processing including plating and surface conditioning

• Short-run prototyping and full-scale production