Zinc Alloy Zamak 5
ASTM Zamak 5 · UNS Z35531
Zamak 5 is Zamak 3 with about 1% copper added for higher strength and hardness (Z35531, AC41A, Mazak 5), and it is the standard die-casting zinc in much of Europe.
Values for the As Cast condition
Zamak 5 tempers and conditions
Zamak 5 is supplied in 4 conditions, soft to hard. As Cast is the default FabDigit quotes; the values on this page are for it.
Compare all 4 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
sand or permanent-mould cast section | For prototypes, tooling aids and thick sections where die casting is not available; coarser grain gives clearly lower strength and ductility. | 175 | 210 | 2.5 | 70 HB | 26 % IACS |
Long-term / accelerated natural-aged design values | Use these lower strength / higher ductility numbers for long-life structural design, since Zamak naturally ages at room temperature. | 225 | 269 | 16 | 80 HB | 27 % IACS |
3–6 h at 100 °C for dimensional stability | Choose when tight dimensional stability is needed on precision castings (gauges, gears, optical mounts) before machining or plating. | 255 | 310 | 9 | 87 HB | 26.5 % IACS |
As CastDefault hot-chamber die cast, no post-treatment | Standard supplied condition for die-cast Zamak 5 parts; use for typical strength/hardness design values. | 268 | 328 | 7 | 91 HB | 26 % IACS |
Supply forms, finishes and certifications
Ways Zamak 5 is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
Ingot | Remelt alloy ingot to ASTM B240 / GB/T 8738 | Supply form |
What is Zamak 5?
Zamak 5 is Zamak 3 with about 1% copper added for higher strength and hardness (Z35531, AC41A, Mazak 5), and it is the standard die-casting zinc in much of Europe. As-cast values are roughly 268 MPa yield, 328 MPa tensile, 7% elongation and 91 HB, with a machinability rating of 85; it is available as die castings, stabilized and aged parts, gravity castings and ingot. The higher copper reduces elongation and creep stability relative to Zamak 3, and service is capped near 100 °C. It is not practically fusion welded; use Zamak 3 where maximum ductility and plating consistency are needed. Zamak 5 has a density of 6.6 g/cm³ (0.238 lb/in³), lighter than 64% of zinc alloy grades. It melts at 380°C (716 °F). Zamak 5 has a yield strength of 268 MPa (38.9 ksi) and a tensile strength of 328 MPa (47.6 ksi) — stronger than 79% of zinc alloy grades. Elongation at break is 7% and the elastic modulus is 96 GPa (13.9 Msi).
What is Zamak 5 used for?
- Automotive fittings and brackets
- Padlock bodies
- Door and window hardware
- Plated bathroom and furniture fittings
- Pump and valve housings
- Small gear and lever components
- Electrical enclosure parts
Advantages
- Polishes to a fine finish — 85/100, better than 89% of zinc alloy grades
- High strength — 268 MPa (38.9 ksi), better than 79% of zinc alloy grades
Zamak 5 properties
Typical room-temperature values for Zamak 5-As Cast; bars are the position among zinc alloy grades.
Physical3
Zamak 5 has a density of 6.6 g/cm³ (0.238 lb/in³), lighter than 64% of zinc alloy grades. It melts at 380°C (716 °F).
Mechanical14
Zamak 5 has a yield strength of 268 MPa (38.9 ksi) and a tensile strength of 328 MPa (47.6 ksi) — stronger than 79% of zinc alloy grades. Elongation at break is 7% and the elastic modulus is 96 GPa (13.9 Msi).
Thermal6
Zamak 5 is rated for continuous service to 100°C (212 °F). It conducts heat at 109 W/m·K (63 BTU/hr·ft·°F), worse than 86% of zinc alloy grades. Thermal expansion is 27.4 µm/m·K (15.2 µin/in·°F).
Electrical3
Zamak 5 conducts electricity at 26 % IACS, worse than 86% of zinc alloy grades.
Chemical & Environmental3
Corrosion resistance is fair (38/100), worse than 71% of zinc alloy grades.
Sustainability4
Producing a kilogram of Zamak 5 takes about 53 MJ of energy and emits 3.4 kg of CO₂ — less than 68% of zinc alloy grades. Typical recycled content is 25%.
Manufacturability8
Zamak 5's machinability is excellent (85/100, better than 89% of zinc alloy grades); weldability poor (15/100); formability poor (20/100).
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 5 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with Zamak 5
Is Zamak 5 easy to machine?
Very free-machining with sharp carbide or HSS tools, high speeds, light feeds and no coolant needed for light cuts; avoid heavy work-hardening-free but gummy chips at low speed.
Can Zamak 5 be welded?
Not practically fusion-welded; joints made by mechanical fastening, adhesives, or soft soldering with zinc-compatible flux — keep heat below ~200 °C to avoid distortion and grain growth.
Can Zamak 5 be formed, bent or molded?
Ideal hot-chamber die-casting alloy: 415–430 °C melt, thin walls to ~0.5 mm, long tool life; allow for natural aging shrinkage (~0.07%) and stabilize precision parts at 100 °C.
Manufacturability
The process limits FabDigit's quote engine applies to Zamak 5. Design inside these and the part quotes instantly; outside them it routes to an engineer.
CNC machining
| Machinability | Excellent85 / 100 |
|---|---|
| Cutting speed (rough / finish) | — / — |
| Minimum wall | — |
| Minimum internal radius | — |
| Drill depth limit | |
| Best surface (machined / polished) | Ra — / — |
| Hardenable after machining | — |
Zamak 5 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 |
|---|---|---|
| AlASTM B86 AC41A | 3.5 – 4.3 | 4 |
| Cu | 0.75 – 1.25 | 1 |
| Mg | 0.03 – 0.08 | 0.05 |
| Fe | ≤ 0.1 | |
| Pbmax — impurity, causes intergranular corrosion | ≤ 0.01 | |
| Cd | ≤ 0 | |
| Sn | ≤ 0 | |
| Nimax (ingot limit) | ≤ 0.02 | |
| ZnSpecial High Grade zinc, 99.99% base | balance |
What surface finishes work on Zamak 5?
Excellent substrate for buffing plus Cu-Ni-Cr electroplating, chromate/trivalent passivation, e-coat or powder paint; never anodize, and keep plating baths pH-controlled to avoid substrate attack.
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 5 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- UNS
- Z35531
- ASTM
- AC41A
- Trade names
- Mazak 5
How much does Zamak 5 cost?
Zamak 5 is a budget-cost zinc alloy ($), cheaper than about 98% 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 5 — frequently asked
What is Zamak 5 used for?
Zamak 5 is typically used for automotive fittings and brackets, padlock bodies, door and window hardware, plated bathroom and furniture fittings, pump and valve housings and small gear and lever components. In short: higher-strength die-cast zinc.
What is the yield strength of Zamak 5?
Zamak 5 has a typical yield strength of 268 MPa (38.9 ksi) and a tensile strength of 328 MPa (47.6 ksi) — stronger than 79% of zinc alloy grades. Strength varies by condition: see the 4 listed tempers.
Is Zamak 5 easy to machine?
Yes — machinability is rated excellent (85/100, better than 89% of zinc alloy grades). Very free-machining with sharp carbide or HSS tools, high speeds, light feeds and no coolant needed for light cuts; avoid heavy work-hardening-free but gummy chips at low speed.
Can Zamak 5 be welded?
Not readily — weldability is rated poor (15/100). Not practically fusion-welded; joints made by mechanical fastening, adhesives, or soft soldering with zinc-compatible flux — keep heat below ~200 °C to avoid distortion and grain growth.
What surface finishes work on Zamak 5?
Excellent substrate for buffing plus Cu-Ni-Cr electroplating, chromate/trivalent passivation, e-coat or powder paint; never anodize, and keep plating baths pH-controlled to avoid substrate attack.
Can Zamak 5 be formed, bent or molded?
Ideal hot-chamber die-casting alloy: 415–430 °C melt, thin walls to ~0.5 mm, long tool life; allow for natural aging shrinkage (~0.07%) and stabilize precision parts at 100 °C.
What is the maximum service temperature of Zamak 5?
Zamak 5 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 5 As Cast and Zamak 5 Aged?
As Cast is the default condition — standard supplied condition for die-cast Zamak 5 parts; use for typical strength/hardness design values. Aged: use these lower strength / higher ductility numbers for long-life structural design, since Zamak naturally ages at room temperature. Yield strength is 268 MPa in As Cast versus 225 MPa in Aged.
How much does Zamak 5 cost?
Zamak 5 is a budget-cost zinc alloy ($), cheaper than about 98% 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 5?
Yes — Zamak 5 is available for CNC machining and casting & forging with instant online pricing. Upload a STEP file to get a price and a DFM check.
Sources
- ASTM B86 — Zinc and Zinc-Aluminum Alloy Foundry and Die Castings — ASTM International (2018)
- ASTM B240 — Zinc and Zinc-Aluminum Alloys in Ingot Form for Castings — ASTM International (2016)
- JIS H 5301 (ZDC1/ZDC2 zinc die castings) — JSA (2009)
- ASM Handbook Vol. 2 — Properties and Selection: Nonferrous Alloys — ASM International (1990)
- NADCA Product Specification Standards for Die Castings — zinc alloy properties — NADCA (2018)
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.