Editorial Technical Reference

Zinc Die Casting

This page explains how Zinc Die Casting is classified within Basic Metal Manufacturing. Technical values and manufacturer relationships are research references; confirm the current specification and supplier evidence for each order.

Technical Definition & Core Assembly

Zinc die casting is a high-precision metal forming process that produces complex, durable parts with excellent dimensional accuracy and surface finish.

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Product Specifications

Technical details and manufacturing context for Zinc Die Casting

Definition

Zinc die casting is used in automotive, electronics, hardware, and consumer goods for components requiring high strength, intricate shapes, and tight tolerances. Parts are specified by material grade (e.g., Zamak 3, Zamak 5), dimensional tolerances, surface finish, and mechanical properties. Grades differ in alloying elements (aluminum, copper, magnesium) affecting strength, ductility, and corrosion resistance. The process yields parts with smooth surfaces, thin walls, and excellent thermal and electrical conductivity.

Working Principle

Molten zinc alloy is injected under high pressure into a steel mold (die) at high speed, filling the cavity and solidifying rapidly. The high pressure ensures precise replication of the mold's details and minimizes porosity. After cooling, the die opens and the part is ejected, ready for secondary operations if needed.

Common Materials

Zamak 3 (ZnAl4Cu1), Zamak 5 (ZnAl4Cu1), Zamak 2 (ZnAl4Cu3), ZA-8 (ZnAl8Cu1), Zinc-Aluminum (ZA-12, ZA-27)

Technical Parameters

Parameter	Typical range	Notes & selection driver
Wall Thickness	0.5–3.0 mm	Typical range for zinc die castings; thinner walls possible with design optimization.
Dimensional Tolerance	±0.05 mm	Typical tolerance for small to medium parts; tighter tolerances achievable.ISO 8062-3
Surface Roughness (Ra)	0.8–1.6 μm	As-cast surface finish; can be improved by polishing or coating.ISO 1302
Tensile Strength	280–400 MPa	Depends on alloy; Zamak 3 typically 283 MPa, Zamak 5 331 MPa.ASTM B86
Yield Strength	200–300 MPa	Typical range for zinc die casting alloys.ASTM B86
Elongation at Break	2–10 %	Varies with alloy; Zamak 3 has ~10%, Zamak 5 ~7%.ASTM B86
Hardness (Brinell)	82–105 HB	Typical range for zinc die casting alloys.ASTM B86
Maximum Operating Temperature	100–120 °C	Continuous service; higher temperatures reduce mechanical properties.
Corrosion Resistance	Good	Zinc alloys offer good corrosion resistance; can be enhanced with coatings.ASTM B117
Density	6.6–7.2 g/cm³	Depends on alloy composition.ASTM B86
Thermal Conductivity	100–120 W/m·K	Good thermal conductivity for heat dissipation applications.
Electrical Conductivity	25–30 % IACS	Relative to copper; suitable for EMI shielding and electrical components.
Minimum Draft Angle	0.5–1.0 °	Required for easy ejection from die; varies with texture and depth.
Maximum Part Weight	0.1–5 kg	Typical range; larger parts possible with specialized machines.
Casting Cycle Time	10–60 s	Depends on part size and complexity; high production rates.

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Industry Taxonomies & Aliases

Commonly used trade names and technical identifiers for Zinc Die Casting.

Published Manufacturer Relationships

Source-reviewed profile relationships currently associated with Zinc Die Casting

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Data Basis

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Preliminary Technical Classification

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