Zamak 5

Zamak 5 is a high-strength zinc alloy with superior corrosion resistance and excellent casting properties. Known for its enhanced mechanical performance compared to Zamak 3, Zamak 5 is widely used in applications requiring structural integrity and durability. This alloy is particularly favored in automotive, electrical, and industrial equipment industries, where parts need to withstand mechanical stress and environmental exposure.

At Neway, we specialize in Zamak 5 die casting services with integrated CNC machining, tooling, and surface finishing capabilities to ensure that your parts are made to the highest standards of precision and performance.

Description

Zamak 5 is a high-strength zinc alloy with exceptional durability, corrosion resistance, and casting fluidity, making it ideal for automotive, industrial, and electronics applications.

Key Characteristics of Zamak 5

Zamak 5 is an alloy that contains zinc, aluminum, copper, and magnesium. It is known for its higher strength and better corrosion resistance than Zamak 3, making it suitable for more demanding applications.

Zamak 5's improved strength and durability make it ideal for parts exposed to mechanical stress, high temperatures, and corrosive environments.

Chemical Composition of Zamak 5

Zamak 5’s copper content provides enhanced strength and resistance to wear, while aluminum improves its casting fluidity and heat resistance.

Mechanical Properties of Zamak 5 Zinc Alloy

Zamak 5 is typically chosen for applications that require both high strength and moderate to high resistance to corrosion and wear.

The higher tensile strength and fatigue resistance of Zamak 5 make it suitable for parts that need to withstand mechanical and environmental stresses.

Benefits of Using Zamak 5 in Die Casting

• Superior Strength: Zamak 5 offers higher strength than Zamak 3, making it ideal for parts exposed to greater stress and load-bearing conditions.

• Corrosion Resistance: It provides enhanced corrosion resistance, especially in environments where parts are exposed to moisture, salts, or chemicals.

• Excellent Fluidity: Zamak 5 has excellent casting characteristics, allowing intricate designs and thin-walled parts to be molded precisely.

• Good Machinability: It is easy to machine and finish, making it a suitable choice for parts that require additional processing after casting.

• Thermal Stability: The alloy performs well in high-temperature environments, maintaining structural integrity and dimensional stability.

Typical Applications of Zamak 5 Die Cast Parts

Zamak 5 is commonly used in industries that require strong, durable, and corrosion-resistant components. Its applications include:

• Automotive: Structural components, engine brackets, and transmission parts

• Industrial Equipment: Pump housings, gear cases, and valve bodies

• Consumer Electronics: Electrical enclosures, electrical connectors, and housing for appliances

• Telecommunications: Outdoor communication devices, junction boxes, and brackets

• Aerospace: Precision mechanical parts, actuators, and housings for electronic equipment

The enhanced mechanical properties of Zamak 5 make it ideal for mission-critical applications where performance, durability, and reliability are non-negotiable.

CNC Machining Considerations for Zamak 5

Zamak 5 offers good machinability, though it requires proper tooling to prevent excessive wear on cutting tools due to its copper content.

Machining Recommendations:

• Tooling: Carbide or TiAlN-coated carbide tools are recommended to reduce tool wear.

• Cutting Speed: Milling: 250–500 m/min; drilling: 100–150 m/min

• Feed Rate: 0.05–0.15 mm/rev, depending on tool size and feature depth

• Coolants: Water-soluble or synthetic coolants are preferred to optimize tool life and surface finish.

• Surface Finish: Achievable Ra ≤ 1.6 µm for parts requiring smooth sealing faces or high-quality finishes.

• Tolerance: ±0.03 mm typical for critical features.

Neway’s CNC machining ensures precision and efficiency in machining Zamak 5 die cast parts, meeting tight tolerances and surface quality standards.

Surface Treatments for Zamak 5 Parts

Zamak 5 parts can undergo various surface treatments to improve corrosion resistance, wear resistance, and appearance:

• Anodizing: Provides a protective oxide layer that enhances corrosion resistance.

• Powder Coating: Ideal for outdoor or marine applications where enhanced protection is required.

• Painting: Suitable for parts requiring aesthetic finishes or UV resistance.

• Tumbling: Used to smooth parts and remove sharp edges before further finishing.

All surface treatments are carefully monitored to ensure compliance with quality standards such as ASTM B117 (salt spray) and ISO 2409 (adhesion testing).

Why Choose Neway for Zamak 5 Die Casting?

Neway offers full-service Zamak 5 die casting solutions, including design consultation, rapid prototyping, and mass production capabilities. We leverage advanced mold design, die-casting optimization, and precision post-processing to deliver high-performance components that meet the highest strength, durability, and reliability standards.

FAQs:

1. How does Zamak 5 compare to Zamak 3 regarding strength and corrosion resistance?

2. What are the most common applications for Zamak 5 in the automotive industry?

3. Can Zamak 5 be anodized or powder-coated for added protection?

4. How do machining speeds for Zamak 5 compare to other zinc alloys?

5. What industries benefit most from using Zamak 5 for die-cast parts?