Zinc Alloy Zamak 5 · finish state · default condition
Zinc Alloy Zamak 5 As Cast
Properties of the As Cast condition, compared with the other Zamak 5 tempers.
Standard supplied condition for die-cast Zamak 5 parts; use for typical strength/hardness design values.
What is Zamak 5 As Cast?
Zamak 5 As Cast is Zamak 5 supplied in the As Cast condition — standard supplied condition for die-cast Zamak 5 parts; use for typical strength/hardness design values. Zamak 5 As Cast 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). Zamak 5 As Cast 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).
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 As Cast properties
Typical room-temperature values for Zamak 5 As Cast — 9 properties are specific to this condition; the rest are grade-level values shared by every Zamak 5 temper. Each bar shows where the value sits among the zinc alloy grades in FabDigit's library — further right is higher.
Physical3
Zamak 5 As Cast 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).
Mechanical12
Zamak 5 As Cast 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 As Cast 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 As Cast 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 As Cast 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%.
Manufacturability7
Zamak 5 As Cast'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.
Other Zamak 5 tempers and conditions
Zamak 5 is also supplied in 4 other conditions. The full side-by-side table is on the Zamak 5 overview.
- As CastDefaultStandard supplied condition for die-cast Zamak 5 parts; use for typical strength/hardness design values.268 MPa yield · 91 HB
Working with Zamak 5 As Cast
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.
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.
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 | — |
Zamak 5 As Cast — frequently asked
What is Zamak 5 As Cast used for?
Zamak 5 As Cast 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 As Cast?
Zamak 5 As Cast 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 5 listed tempers.
Is Zamak 5 As Cast 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 As Cast 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 As Cast?
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 As Cast 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 As Cast?
Zamak 5 As Cast 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.
Can FabDigit make parts in Zamak 5 As Cast?
Yes — Zamak 5 As Cast 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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.