Zinc Zamak 5

Zamak 5 is the high-strength variant of the zinc-aluminum alloy family, distinguished by its 1% copper addition. This chemical modification results in significantly higher tensile strength, greater hardness, and improved creep resistance compared to Zamak 3, though it sacrifices a degree of ductility. Jucheng Precision provides expert CNC machining services for Zamak 5, catering to industries that require robust, high-performance zinc components. Whether we are machining functional prototypes to validate heavy-duty automotive latch designs or performing precision secondary operations on die-cast gears, our IATF 16949 certified facility ensures every Zamak 5 part meets the highest mechanical and dimensional standards.

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Zamak 5

Zamak 5 Machining Capabilities

Capability Technical Description Jucheng Advantage
High-Strength Prototyping Machining Zamak 5 from solid block to simulate heavy-duty die-cast parts for mechanical testing. Our prototypes accurately represent the superior tensile strength and hardness of production Zamak 5 parts, ensuring reliable FEA validation.
Precision Gear Hobbing Milling and hobbing high-precision zinc gears and splines for small mechanism drives. We achieve high gear quality standards with exceptional tooth surface finish, reducing noise and wear in the final assembly.
Complex Secondary Machining Performing intricate post-cast operations on Zamak 5 parts, including deep boring and cross-hole drilling. Our multi-axis CNC centers ensure perfect geometric alignment between cast features and machined precision bores.
Advanced Surface Prep Preparing Zamak 5 surfaces for high-performance coatings like hard chrome or decorative vacuum metallization. We deliver Ra 0.4μm finishes that maximize coating adhesion and provide a flawless mirror look for premium hardware.

Fabrication Guidelines for Zamak 5 Zinc Alloy

Effect of Copper Content:
Zamak 5 contains ~1% copper, making it harder and stronger than Zamak 3. Tip: This copper content also makes it slightly more abrasive to tools; we use high-quality coated carbide for extended tool life.

Creep Resistance:
Zamak 5 has better creep resistance (resistance to deformation under constant load) than Zamak 3. Tip: It is the preferred zinc alloy for structural parts subject to continuous stress.

Ductility Consideration:
While stronger, Zamak 5 is less ductile than Zamak 3. Tip: Avoid sharp internal corners or thin sections that require post-machining bending or crimping, as the material is more prone to cracking.

Tooling Sharpness:
To maintain the excellent surface finish Zamak 5 is known for, we maintain ultra-sharp cutting edges to prevent “tearing” the material, ensuring clean, burr-free threads and edges.

Primary Applications

Automotive Hardare
Door handles, seat belt components, and latch mechanisms requiring higher strength and wear resistance than standard zinc.

Industrial Tools
Wrenches, pulley wheels, and specialized clamps that benefit from the alloy’s high hardness and impact resistance.

Building Hardware
High-security lock bodies and heavy-duty hinges where structural integrity and durability are critical.

Appliance Components
Gears and internal structural brackets for washing machines and mixers that operate under high mechanical loads.

Properties

Density 6.60 g/cm³
Tensile Strength 331 MPa
Yield Strength 295 MPa
Hardness 91 HB (Brinell)
Elongation at Break 7%
Thermal Conductivity 109 W/m-K
Electrical Conductivity 26% IACS
Melting Point 380 - 386 °C
Machinability Rating Good
Corrosion Resistance Good
Max Part Size 2000 x 800 x 600 mm