Zinc Alloy Zamak 2
ASTM Zamak 2 · UNS Z35541
Zamak 2 is the highest-copper member of the Zamak zinc-aluminum die-casting family (Z35541, AC43A, Mazak 2), with copper added to raise hardness and wear resistance above Zamak 3 and Zamak 5.
Values for the As Cast condition
Zamak 2 tempers and conditions
Zamak 2 is supplied in 3 conditions, soft to hard. As Cast is the default FabDigit quotes; the values on this page are for it.
Compare all 3 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
sand or permanent-mould cast tooling stock | Pick for cast-to-shape sheet-metal press dies, blow-mould and prototype tooling machined from cast slabs; coarser grain gives lower strength than die cast. | 180 | 235 | 2 | 90 HB | 25 % IACS |
Aged/Stabilized | Use these de-rated values for long-service or dimensionally stabilized parts, where the metastable cast structure has decomposed. | 255 | 296 | 2 | 98 HB | 26 % IACS |
As CastDefault hot-chamber die cast, as-manufactured | Standard supply condition for pressure die-cast Zamak 2 parts; highest strength and hardness of the Zamak family. | 283 | 359 | 7 | 100 HB | — |
What is Zamak 2?
Zamak 2 is the highest-copper member of the Zamak zinc-aluminum die-casting family (Z35541, AC43A, Mazak 2), with copper added to raise hardness and wear resistance above Zamak 3 and Zamak 5. In the as-cast condition it holds about 283 MPa yield, 359 MPa tensile, 7% elongation and 100 HB, and it is supplied as hot-chamber die castings, gravity-cast slabs and machined blanks (machinability rating 80). Service temperature is limited to roughly 100 °C and the alloy is not a structural welding alloy. It is harder to plate and less commonly die cast than Zamak 3, so Zamak 5 is the usual alternative when plating and supply matter more than peak hardness. Zamak 2 has a density of 6.6 g/cm³ (0.238 lb/in³), lighter than 64% of zinc alloy grades. It melts at 379°C (714 °F). Zamak 2 has a yield strength of 283 MPa (41 ksi) and a tensile strength of 359 MPa (52.1 ksi) — stronger than 86% of zinc alloy grades. Elongation at break is 7% and the elastic modulus is 96 GPa (13.9 Msi).
What is Zamak 2 used for?
- Door hardware
- Padlock bodies
- Lock cylinders and latch housings
- Wear-resistant bushings and sleeves
- Gravity-cast slabs for press and blow-mould tooling
- Hand-tool bodies and handles
- Gear and cam components
Advantages
- High strength — 283 MPa (41 ksi), better than 86% of zinc alloy grades
Zamak 2 properties
Typical room-temperature values for Zamak 2-As Cast; bars are the position among zinc alloy grades.
Physical3
Zamak 2 has a density of 6.6 g/cm³ (0.238 lb/in³), lighter than 64% of zinc alloy grades. It melts at 379°C (714 °F).
Mechanical12
Zamak 2 has a yield strength of 283 MPa (41 ksi) and a tensile strength of 359 MPa (52.1 ksi) — stronger than 86% of zinc alloy grades. Elongation at break is 7% and the elastic modulus is 96 GPa (13.9 Msi).
Thermal6
Zamak 2 is rated for continuous service to 100°C (212 °F). It conducts heat at 105 W/m·K (60.7 BTU/hr·ft·°F), worse than 100% of zinc alloy grades. Thermal expansion is 27.8 µm/m·K (15.4 µin/in·°F).
Electrical3
Zamak 2 conducts electricity at 25 % IACS, worse than 100% of zinc alloy grades.
Chemical & Environmental3
Corrosion resistance is fair (40/100), better than 50% of zinc alloy grades.
Sustainability4
Producing a kilogram of Zamak 2 takes about 56 MJ of energy and emits 3.6 kg of CO₂ — more than 79% of zinc alloy grades. Typical recycled content is 25%.
Manufacturability8
Zamak 2's machinability is very good (80/100, better than 64% of zinc alloy grades); weldability poor (20/100); formability poor (15/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the zinc alloy family
Yield strength against density for every zinc alloy grade FabDigit runs. Zamak 2 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with Zamak 2
Is Zamak 2 easy to machine?
Cuts very freely with sharp carbide or HSS tools at high speed, little or no coolant, excellent surface finish and tight tolerances.
Can Zamak 2 be welded?
Not a structural welding alloy; only zinc-alloy TIG/torch repair of castings, and soft soldering with zinc-compatible flux.
Can Zamak 2 be formed, bent or molded?
Hot-chamber die casting at ~415–430 °C with thin walls and fine detail; also gravity cast into slabs for press/blow-mould tooling.
Manufacturability
The process limits FabDigit's quote engine applies to Zamak 2. Design inside these and the part quotes instantly; outside them it routes to an engineer.
CNC machining
| Machinability | Excellent80 / 100 |
|---|---|
| Cutting speed (rough / finish) | — / — |
| Minimum wall | — |
| Minimum internal radius | — |
| Drill depth limit | |
| Best surface (machined / polished) | Ra — / — |
| Hardenable after machining | — |
Zamak 2 chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Al | 3.9 – 4.3 | 4.1 |
| Cu | 2.7 – 3.3 | 3 |
| Mg | 0.03 – 0.05 | 0.04 |
| Feimpurity max (die casting) | ≤ 0.1 | |
| Pbimpurity max | ≤ 0.01 | |
| Cdimpurity max | ≤ 0 | |
| Snimpurity max | ≤ 0 | |
| Znspecial high grade zinc, 99.99% base | balance |
What surface finishes work on Zamak 2?
Buffs to a bright finish; typical routes are Cu-Ni-Cr electroplating, chromate/phosphate conversion plus paint or powder coat — do not anodize.
Surface treatments FabDigit runs on zinc alloy parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Organic Coating
Equivalent designations
Standards and trade names that resolve to Zinc Alloy Zamak 2 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- UNS
- Z35541
- ASTM
- AC43A
- Trade names
- KirksiteMazak 2
How much does Zamak 2 cost?
Zamak 2 is a standard-cost zinc alloy ($$), cheaper than about 81% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Zamak 2 — frequently asked
What is Zamak 2 used for?
Zamak 2 is typically used for door hardware, padlock bodies, lock cylinders and latch housings, wear-resistant bushings and sleeves, gravity-cast slabs for press and blow-mould tooling and hand-tool bodies and handles. In short: high-strength die-cast zinc.
What is the yield strength of Zamak 2?
Zamak 2 has a typical yield strength of 283 MPa (41 ksi) and a tensile strength of 359 MPa (52.1 ksi) — stronger than 86% of zinc alloy grades. Strength varies by condition: see the 3 listed tempers.
Is Zamak 2 easy to machine?
Yes — machinability is rated very good (80/100, better than 64% of zinc alloy grades). Cuts very freely with sharp carbide or HSS tools at high speed, little or no coolant, excellent surface finish and tight tolerances.
Can Zamak 2 be welded?
Not readily — weldability is rated poor (20/100). Not a structural welding alloy; only zinc-alloy TIG/torch repair of castings, and soft soldering with zinc-compatible flux.
What surface finishes work on Zamak 2?
Buffs to a bright finish; typical routes are Cu-Ni-Cr electroplating, chromate/phosphate conversion plus paint or powder coat — do not anodize.
Can Zamak 2 be formed, bent or molded?
Hot-chamber die casting at ~415–430 °C with thin walls and fine detail; also gravity cast into slabs for press/blow-mould tooling.
What is the maximum service temperature of Zamak 2?
Zamak 2 is rated for continuous use to about 100°C (212 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between Zamak 2 As Cast and Zamak 2 Aged?
As Cast is the default condition — standard supply condition for pressure die-cast Zamak 2 parts; highest strength and hardness of the Zamak family. Aged: use these de-rated values for long-service or dimensionally stabilized parts, where the metastable cast structure has decomposed. Yield strength is 283 MPa in As Cast versus 255 MPa in Aged.
How much does Zamak 2 cost?
Zamak 2 is a standard-cost zinc alloy ($$), cheaper than about 81% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Can FabDigit make parts in Zamak 2?
Yes — Zamak 2 is available for CNC machining with instant online pricing. Upload a STEP file to get a price and a DFM check.
Sources
- ASTM B86 — Zinc and Zinc-Aluminum (ZA) Alloy Foundry and Die Castings (alloy AC43A) — ASTM International (2018)
- ASM Handbook Vol. 2 — Properties and Selection: Nonferrous Alloys (Zinc Alloys) — ASM International (1990)
- Zinc Die Casting Alloys Engineering Properties — ILZRO / IZA (2010)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.