Castings Technical Info

Discover what is possible when you review our die castings technical information. Connor Corporation uses a set of specific aluminum and zinc alloys that give you an advantage at several stages of the development process. Learn more about die castings and the increase in production that is possible when you collaborate with our team.

Zinc Die Casting Alloys

ZAMAK 3: (ZP3, ZL3, ZP0400, ZnAl4, ZDC2)
Zamak 3 is the most widely used zinc alloy in North America & Asia. Its popularity is due to an excellent balance of desirable physical and mechanical properties, superb castability and long-term dimensional stability. Zamak 3 also offers excellent finishing characteristics for plating, painting and chromate treatments. It is the “standard” by which other zinc alloys are rated in terms of die casting.

Zamak 5: (ZP5, ZL5, ZP0410, ZNAl4CU1, ZDC1)
Alloy 5 is the most widely used zinc alloy in Europe. No. 5 has excellent castability characteristics and improved creep performance over Zamak 3. Zamak 5 castings are also marginally stronger and harder than Zamak 3. However, these improvements are accompanied by a reduction in ductility that can affect formability during secondary bending, riveting, swaging or crimping operations. Zamak 5 contains an addition of 1% copper which accounts for these property changes. When an extra measure of tensile performance is needed, Zamak 5 castings are recommended. The alloy is readily plated, finished and machined, comparable to Zamak 3.

Zamak 2: (ZP2, ZL2, ZP0430, ZNAl4CU3, KirkSite)
Zamak 2 offers the highest strength and hardness of the conventional zinc alloys. The high copper content (3%) in Zamak 2 results in property changes upon long-term aging. These changes include slight dimensional growth, lower elongation and reduced impact performance (to levels similar to aluminum alloys) for die cast products. Zamak 2 exhibits excellent castability and maintains higher strength and hardness levels after long-term aging. Zamak 2 is a good bearing material and may eliminate bushings and wear inserts in die-cast designs.

Zamak 7: (ZL7)
Zamak 7 is a modification of Zamak 3 with lower magnesium content and tighter impurities specification. This results in improved casting fluidity, ductility and surface finish, making the alloy popular where the die caster is making thin-walled components requiring a good surface finish.

ZA-8: (ZP8)
A good gravity casting alloy, ZA-8 can also be hot chamber die cast and is readily plated and finished using standard procedures for conventional zinc alloys. When the performance of Zamak 3 or Zamak 5 is in question, ZA-8 is often the die casting choice because of high strength and creep properties and efficient hot chamber castability.

Zinc Die Casting Tolerances

Inside diameters: +/- 0.15 mm

Linear dimensions: +/- 0.02 mm

Minimum wall thickness: 0.5 mm for small parts & 1.0mm for large parts

Draft: 0.1 degrees for round holes, 0.5 degrees per side for internal walls & 0.25 degree per side for external walls.

Maximum parting line mismatch – 0.1 mm

Maximum Depths of Cored Holes

Hole Diameter mm Blind Hole max depth mm Thru-Hole max depth mm
3 9 24
4 20 37
5 30 47
6 45 57
7 60 70
8 75 80
9 90 90
10 100 100
11-20 10x diameter 10x diameter
>20 12x diameter 12x diameter

Courtesy of IZA IZA logo

Aluminum Die Casting Alloys

A380 (ADC10)
A380 is the most widely used aluminum alloy in North America. Its popularity is due to its ease of casting balanced with desirable physical and mechanical properties. It’s also popular for cosmetic applications.

A383 (ADC12)
A383 is the most widely used aluminum alloy in Asia. Its popularity is due to ease of fill which makes it the choice for thin-wall applications. It’s also more resistant to heat checking.

AlSi9Cu3 is a popular aluminum alloy in Europe. Its popularity is due to its ease of casting balanced with desirable physical and mechanical properties such as good heat transfer characteristics. It’s ideal for high-temperature applications.

Aluminum Die Casting Tolerances

Inside Diameters: +/- 0.03 mm
Linear Dimensions: +/- 0.05 mm
Draft: 1.0 Degree per Side
Minimum Wall Thickness: 0.8 mm for Small Parts and 1.2mm for Large Parts
Maximum Parting Line Mismatch – 0.4 mm

Contact us today for the die castings technical information your engineering team needs. We proudly serve clients from across North America.