ZAMAK (or Zamac, formerly

trademark A trademark (also written trade mark or trade-mark) is a form of intellectual property that consists of a word, phrase, symbol, design, or a combination that identifies a Good (economics and accounting), product or Service (economics), service f ...

ed as MAZAK) is an eclectic family of

alloy An alloy is a mixture of chemical elements of which in most cases at least one is a metal, metallic element, although it is also sometimes used for mixtures of elements; herein only metallic alloys are described. Metallic alloys often have prop ...

s with a base metal of

zinc Zinc is a chemical element; it has symbol Zn and atomic number 30. It is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed. It is the first element in group 12 (IIB) of the periodic tabl ...

and alloying elements of

aluminium Aluminium (or aluminum in North American English) is a chemical element; it has chemical symbol, symbol Al and atomic number 13. It has a density lower than that of other common metals, about one-third that of steel. Aluminium has ...

magnesium Magnesium is a chemical element; it has Symbol (chemistry), symbol Mg and atomic number 12. It is a shiny gray metal having a low density, low melting point and high chemical reactivity. Like the other alkaline earth metals (group 2 ...

, and

copper Copper is a chemical element; it has symbol Cu (from Latin ) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkish-orang ...

. Zamak alloys are part of the zinc aluminium alloy family; they are distinguished from the other ZA alloys because of their constant 4% aluminium composition. The name ''zamak'' is an

acronym An acronym is a type of abbreviation consisting of a phrase whose only pronounced elements are the initial letters or initial sounds of words inside that phrase. Acronyms are often spelled with the initial Letter (alphabet), letter of each wor ...

of the German names for the

metals A metal () is a material that, when polished or fractured, shows a lustrous appearance, and conducts electricity and heat relatively well. These properties are all associated with having electrons available at the Fermi level, as against no ...

of which the alloys are composed: (zinc), , and (copper). The New Jersey Zinc Company developed zamak alloys in 1929. The most common zamak alloy is zamak 3. Besides that, zamak 2, zamak 5 and zamak 7 are also commercially used. These alloys are most commonly die cast. Zamak alloys (particularly #3 and #5) are frequently used in the

spin casting Spin or spinning most often refers to: * Spin (physics) or particle spin, a fundamental property of elementary particles * Spin quantum number, a number which defines the value of a particle's spin * Spinning (textiles), the creation of yarn or thr ...

industry. A large problem with early zinc die casting materials was zinc pest, owing to impurities in the alloys. Zamak avoided this by the use of 99.99% pure zinc metal, produced by New Jersey Zinc's use of a refluxer as part of the

refining Refining is the process of purification of a (1) substance or a (2) form. The term is usually used of a natural resource that is almost in a usable form, but which is more useful in its pure form. For instance, most types of natural petroleum w ...

process. Zamak can be electroplated, wet painted, and chromate conversion coated well.

Mazak

In the early 1930s, Morris Ashby in Britain had licensed the New Jersey zamak alloy. The 99.99%-purity refluxer zinc was not available in Britain and so they acquired the right to manufacture the alloy using a locally available electrolytically refined zinc of 99.95% purity. This was given the name Mazak, partly to distinguish it from zamak and partly from the initials of Morris Ashby. In 1933, National Smelting licensed the refluxer patent with the intent of using it to produce 99.99% zinc in their plant at Avonmouth.

Standards

Zinc alloy chemical composition standards are defined per country by the standard listed below: Zamak goes by many different names based on standard and/or country: The short European designation code breaks down as follows (using ZL0430 as the example): * Z is the material (Z = zinc) * P is the use (P = pressure die casting (casting), L = ingot) * 04 is the percent aluminum (04 = 4% aluminum) * 3 is the percent copper (3 = 3% copper)

Zamak 2

Zamak 2 has the same composition as zamak 3 with the addition of 3% copper in order to increase strength by 20%, which also increases the price. Zamak 2 has the greatest strength out of all the zamak alloys. Over time it retains its strength and hardness better than the other alloys; however, it becomes more brittle, shrinks, and is less elastic. Zamak 2 is also known as Kirksite when gravity cast for use as a die. It was originally designed for low volume sheet metal dies.. It later gained popularity for making short run

injection molding Injection moulding (U.S. spelling: injection molding) is a manufacturing process for producing parts by injecting molten material into a mould, or mold. Injection moulding can be performed with a host of materials mainly including metals (for ...

dies. It is also less commonly used for non-sparking tools and

mandrel A mandrel, mandril, or arbor is a tapered tool against which material can be forged, pressed, stretched or shaped (e.g., a ring mandrel - also called a triblet - used by jewellers to increase the diameter of a wedding ring), or a flanged or t ...

s for metal spinning.

KS

The KS alloy was developed for spin casting decorative parts. It has the same composition as zamak 2, except with more magnesium in order to produce finer grains and reduce the orange peel effect.

Zamak 3

Zamak 3 is the

de facto standard A ''de facto'' standard is a custom or convention that is commonly used even though its use is not required. is a Latin phrase (literally " of fact"), here meaning "in practice but not necessarily ordained by law" or "in practice or actuality, ...

for the zamak series of zinc alloys; all other zinc alloys are compared to this. Zamak 3 has the base composition for the zamak alloys (96% zinc, 4% aluminum). It has excellent castability and long term dimensional stability. More than 70% of all North American zinc die castings are made from zamak 3.

Zamak 4

Zamak 4 was developed for the Asian markets to reduce the effects of die soldering while maintaining the ductility of zamak 3. This was achieved by using half the amount of copper from the zamak 5 composition.

Zamak 5

Zamak 5 has the same composition as zamak 3 with the addition of 1% copper in order to increase strength (by approximately 10%),

hardness In materials science, hardness (antonym: softness) is a measure of the resistance to plastic deformation, such as an indentation (over an area) or a scratch (linear), induced mechanically either by Pressing (metalworking), pressing or abrasion ...

and corrosive resistance, but reduces

ductility Ductility refers to the ability of a material to sustain significant plastic Deformation (engineering), deformation before fracture. Plastic deformation is the permanent distortion of a material under applied stress, as opposed to elastic def ...

. It also has less dimensional accuracy. Zamak 5 is more commonly used in Europe.

Zamak 7

Zamak 7 has less magnesium than zamak 3 to increase fluidity and ductility, which is especially useful when casting thin wall components. In order to reduce inter-granular corrosion a small amount of nickel is added and impurities are more strictly controlled.

Uses

Common uses for zamak alloys include appliances, bathroom fixtures, die cast toys and automotive industry. Zamak alloys are also used in the manufacture of some firearms such as those from Hi-Point Firearms. In World War 2, zamak alloy buttplates were one of three variations common on Canadian and American-made .303 Lee Enfield rifles, particularly during mid-war production.Charles R. Stratton, British Enfield Rifles, Vol 2, North Cape Publications, 1999 and 2003, pages 106-107

References

External links

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Generic Terms For Zinc Alloys
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Zinc Die Casting Alloy Guide
Zinc alloys