Lead-free10% Higher Strength Than Zamak 31% Copper AdditionMost Popular Zinc Die Casting in EuropeHigher Hardness and Creep Resistance
Zamak 5 zinc die casting alloy with 1% copper addition for increased strength and hardness over Zamak 3. Forms: capping bar, 4-20 ingot, regular bar, and Margash bar.
Zamak 5 is a zinc-aluminum-copper die casting alloy with the same base composition as Zamak 3 plus a 1% copper addition that increases tensile strength by approximately 10%, hardness, and corrosion resistance while reducing ductility compared to Zamak 3. It is the most widely used zinc die casting alloy in Europe and is specified globally when moderately greater strength, hardness, and creep resistance are required over Zamak 3 and the reduction in ductility is acceptable for the application. The copper addition provides a harder stronger matrix that better resists wear and deformation under load – important for functional die cast components such as automotive hardware, locking mechanisms, and structural brackets that must maintain dimensional integrity under service loads. Zamak 5 is also used as an electroplating anode – its zinc-aluminum-copper composition dissolves in certain plating baths to deposit alloy coatings and its ingot and bar forms make it convenient for anode basket loading. The alloy can be finished by all standard methods including mechanical polishing, chemical treatment, organic coatings, and electroplating. Forms: 1/4 lb capping bar, 4-20 lb ingot, approximately 1 lb regular bars, and Margash bar.
Available Forms
1/4# Capping Bar, 4-20 Ingot, Approx. 1 Lb. Regular Bars, Margash Bar
Product Code
89511
Technical Info
Thermal Properties
Melting Point (Solidus)717°F (381°C)
Melting Point (Liquidus)727°F (386°C)
Physical Properties
Density (imperial)0.24 lbs/in³
Density (metric)6.6 g/cm³
Primary ElementsZn · Al · Cu
Lead FreeYes
Key Features
10% Higher Strength Than Zamak 31% Copper AdditionMost Popular Zinc Die Casting in EuropeHigher Hardness and Creep Resistance
Nominal Composition
95% Zn
4% Al
1% Cu
Frequently Asked Questions
Common technical inquiries regarding Zamak 5
Copper in the Zamak 5 matrix forms CuZn4 and epsilon-phase (Cu5Zn8) intermetallics distributed throughout the alloy microstructure. These particles strengthen the matrix by impeding dislocation movement increasing Brinell hardness from approximately 82 (Zamak 3) to 91 (Zamak 5) and tensile strength from 41000 psi to approximately 47600 psi. The same copper-bearing phases reduce ductility - elongation drops from approximately 10% in Zamak 3 to 7% in Zamak 5 making Zamak 5 less suitable for applications requiring deformation before fracture but better for applications needing dimensional stability under load.
Zamak 5 should be selected when the component must resist sustained mechanical loading, wear, or deformation in service - locking mechanisms, cam followers, gear components, automotive brackets, and similar functional hardware where Zamak 3's lower strength is insufficient. For thin-wall decorative castings, enclosures, and covers where impact resistance and ductility are more important than strength Zamak 3 is preferred. In European markets Zamak 5 has historically been the default specification where either alloy would technically suffice.
Margash bars are a specific Zamak ingot form cast to a geometry that fits the gooseneck or shot sleeve of hot chamber zinc die casting machines - the alloy is placed directly in the machine's melt pot and dissolves into the bath during operation. The Margash bar form ensures clean controlled additions without the large ingot pieces that can cause incomplete melting and alloy segregation in the machine pot. It is the standard recharge form for high-production hot chamber zinc die casting operations.
95% Zn / 5% Al zinc-aluminum solder with superior corrosion resistance. Forms: capping bar; 4-20 ingot; and regular bars. Used for aluminum-to-aluminum and aluminum-to-zinc soldering.
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