Which Zamak alloy is best for structural locking components?
Which Zamak Alloy Is Best for Structural Locking Components?
Mechanical Demands of Structural Locking Parts
Structural locking components—such as lock cores, latch actuators, safety interlocks, and mechanical housings—require high strength, dimensional stability, wear resistance, and durability under repeated mechanical load. These parts must also support precise tolerances for moving interfaces, threads, or keyed geometries. Zamak alloys are widely used in these applications due to their excellent castability, consistent mechanical performance, and long-term reliability.
Recommended Zamak Alloy: Zamak 2
Zamak 2 is the best-performing alloy among Zamak grades for structural locking components. It contains approximately 3% copper, which significantly enhances its mechanical strength and fatigue resistance compared to other Zamak alloys.
Key mechanical properties of Zamak 2:
Tensile strength: ~386 MPa
Yield strength: ~283 MPa
Hardness: ~120 Brinell
Excellent creep resistance for dimensional stability over time
Superior wear performance under mechanical cycling
Zamak 2 is ideal for locking systems that require high mechanical loading, metal-on-metal contact, or long-term reliability under torque or impact stress.
Comparison with Other Zamak Alloys
Property | Zamak 3 | Zamak 5 | Zamak 2 (Recommended) |
|---|---|---|---|
Copper Content (%) | ~0.03 | ~1.0 | ~3.0 |
Tensile Strength (MPa) | ~283 | ~331 | ~386 |
Hardness (HB) | ~82 | ~90 | ~120 |
Creep Resistance | Moderate | Good | Excellent |
Fatigue Strength | Good | Very Good | Excellent |
Application Fit | General housings | Handles, moderate load parts | Structural locks, latches |
While Zamak 5 offers increased strength over Zamak 3, only Zamak 2 meets the enhanced mechanical and fatigue performance required for structural locking mechanisms.
Additional Considerations for Locking Applications
Post-cast machining: Threaded zones, cam profiles, and locking grooves can be refined with CNC machining
Wear resistance: Zamak 2 performs well under high cycle rates without coatings; surface finishing can be added for corrosion or cosmetic enhancement
Dimensional precision: Achieved through optimized tool and die design and controlled solidification
Neway’s Manufacturing Capabilities for Structural Components
Neway provides complete production solutions for locking and actuator components with:
High-strength zinc die casting using Zamak 2
Fine-feature tooling for latch cores and locking arms
Surface finishing as required for environmental protection or aesthetics
