Zinc Alloy
ZAMAK 3, 5 & 7
High-purity Zinc Alloys in standard ZAMAK 3, 5, and 7 specifications — manufactured from 99.99% Special High Grade zinc feedstock. Engineered for precision pressure die casting, structural automotive components, electrical enclosures, and high-performance hardware fittings.
Engineering-Grade Zinc Alloys for High-Tolerance Die Casting
Bhatti Chemicals Industry manufactures and supplies premier ZAMAK zinc-aluminium-copper-magnesium alloys engineered to satisfy stringent automotive, mechanical, and architectural casting requirements. Formulated exclusively using 99.99% high-purity electrolytic base zinc, our alloys maintain ultra-low trace levels of lead, cadmium, and tin (< 0.005%) to guarantee total immunity against intergranular corrosion and dimensional distortion.
Zinc die casting alloys offer unmatched production advantages over aluminium and magnesium: lower casting temperatures (~420°C) which extend steel die tooling life fourfold, superior net-shape precision (±0.02 mm), natural electro-magnetic shielding (EMI/RFI), and effortless surface finishing for mirror-chrome plating, powder coating, or electrophoresis.
Whether producing high-ductility thin-wall electronic housings with ZAMAK 7, structural automotive gear assemblies with ZAMAK 5, or general consumer hardware with ZAMAK 3, our metallurgical foundry delivers exact chemistry consistency across every heat.
- Ultra-Low Impurities: Pb < 0.005%, Cd < 0.004%, Sn < 0.003% prevent intercrystalline failure.
- Exceptional Fluidity: Flawless cavity fill for complex thin-walled castings down to 0.6 mm.
- Tooling Longevity: Non-abrasive melt protects hot-chamber die casting machines and molds.
- Complete Traceability: Heat-stamped ingots accompanied by batch chemical COA.
- 100% Recyclable: Sustainable circular metallurgy with negligible melt oxidation losses.
ZAMAK Zinc Die Casting Grades
Tailored mechanical, ductile, and finishing characteristics engineered to match specialized die casting geometries and duty cycles.
ZAMAK 3
The global benchmark die casting alloy (ASTM AG40A)
- Zinc (Zn) Balance (96%)
- Aluminium (Al) 3.5 – 4.3%
- Magnesium (Mg) 0.02 – 0.05%
- Tensile Strength 283 MPa
- Elongation 10% in 50mm
- Brinell Hardness 82 HB
Offers the most stable combination of physical properties, dimensional longevity, castability, and ease of electroplating. The standard choice for automotive door components, brackets, bathroom fixtures, and consumer electronics.
ZAMAK 5
Copper-reinforced structural alloy (ASTM AC41A)
- Zinc (Zn) Balance (95%)
- Aluminium (Al) 3.5 – 4.3%
- Copper (Cu) 0.75 – 1.25%
- Magnesium (Mg) 0.03 – 0.06%
- Tensile Strength 330 MPa
- Brinell Hardness 91 HB
1% copper addition delivers ~15% higher tensile strength and enhanced creep resistance. Recommended for heavy-duty automotive gears, industrial machinery brackets, high-security deadbolts, and parts subjected to moderate service temperatures.
ZAMAK 7
High-fluidity ultra-thin wall grade (ASTM AG40B)
- Zinc (Zn) Balance (96%)
- Aluminium (Al) 3.5 – 4.3%
- Magnesium (Mg) 0.005 – 0.020%
- Nickel (Ni) 0.005 – 0.020%
- Tensile Strength 283 MPa
- Elongation 13% (Max Ductility)
Formulated with reduced magnesium and controlled nickel addition to optimize melt surface tension. Achieves superior fluidity for casting intricate thin-walled telecommunications frames, connector shields, and components requiring post-cast crimping.
Chemical & Mechanical Comparison Matrix
Chemical limits compliant with ASTM B240 standard specifications for zinc alloy ingots for die castings.
| Constituent / Property | ZAMAK 3 | ZAMAK 5 | ZAMAK 7 | Test Method |
|---|---|---|---|---|
| Base Zinc (Zn) Purity | Balance (99.99%) | Balance (99.99%) | Balance (99.99%) | Optical Emission (OES) |
| Aluminium (Al) Content | 3.50 – 4.30% | 3.50 – 4.30% | 3.50 – 4.30% | ASTM B240 / OES |
| Copper (Cu) Content | ≤ 0.25% | 0.75 – 1.25% | ≤ 0.25% | ASTM B240 / OES |
| Magnesium (Mg) Content | 0.020 – 0.050% | 0.030 – 0.060% | 0.005 – 0.020% | ASTM B240 / OES |
| Iron (Fe) Maximum | 0.050% | 0.050% | 0.050% | Spectrophotometry |
| Lead (Pb) Maximum | 0.005% | 0.005% | 0.003% | ICP-OES High-Purity |
| Cadmium (Cd) Maximum | 0.004% | 0.004% | 0.003% | ICP-OES Trace Analysis |
| Tin (Sn) Maximum | 0.003% | 0.003% | 0.002% | ICP-OES Trace Analysis |
| Tensile Strength (MPa) | 283 MPa | 330 MPa | 283 MPa | ASTM E8 Standard |
| Yield Strength 0.2% Offset | 221 MPa | 250 MPa | 221 MPa | ASTM E8 Standard |
| Elongation in 50 mm (%) | 10% | 7% | 13% | ASTM E8 Tensile Test |
| Brinell Hardness (HB) | 82 HB | 91 HB | 80 HB | ASTM E10 (500 kg, 10mm) |
| Melting Range (°C) | 381 – 387 °C | 380 – 386 °C | 381 – 387 °C | Calibrated Pyrometry |
| Specific Density | 6.6 g/cm³ | 6.7 g/cm³ | 6.6 g/cm³ | Hydrostatic Method |
6-Stage Precision Alloying & Casting Process
Every metric ton of Zinc Alloy produced at Bhatti Chemicals undergoes rigorous thermodynamic control and elemental verification.
Electrolytic SHG Feedstock
Only verified 99.99% Special High Grade zinc is charged into the induction furnace to eliminate pernicious contaminants like tin, lead, and cadmium.
Stoichiometric Alloying
High-purity master alloys of aluminium (Al 99.9%), electrolytic copper, and magnesium are weighed to ±0.01 kg accuracy to meet exact target formulations.
Induction Melting & Degassing
Clean medium-frequency induction heating maintains uniform melt temperature (440–460°C) with inert gas rotary degassing to purge dissolved hydrogen and dross.
Real-Time Spectrometry (OES)
Sample pins are spark-analyzed via Optical Emission Spectrometry prior to tapping, certifying all 12 elemental channels meet ASTM B240 chemistry windows.
Continuous Ingot Casting
Molten alloy is cast into precision steel molds with controlled water-cooling stages to produce fine-grained, segregation-free ingot microstructures.
Heat Stamping & Bundling
Solidified ingots are stamped with the alloy grade and melt batch number, stacked into ~1 MT pallets, and secured with four high-tensile steel straps.
Industrial Die Casting Applications
ZAMAK zinc alloys offer unrivaled fluid net-shape casting, enabling high-speed automated production across mission-critical industries.
Automotive & Transport
Exterior door handles, rearview mirror brackets, seatbelt retractors, sunroof mechanisms, carburetor fittings, and fuel delivery housings.
Security & Lock Hardware
High-security lock cylinders, architectural deadbolts, decorative escutcheons, window cremone bolts, heavy-duty hinges, and cabinet latches.
Electronics & EMI Shielding
Shielded connector shells, telecommunication chassis, heat sinks, fiber optic transceivers, and EMI/RFI-sensitive electronic housings.
Plumbing & Sanitary Fittings
Bathroom faucets, diverter valves, shower control bodies, decorative water handles, and chrome-plated fluid containment fittings.
Industrial Machinery & Motors
Precision gears, stepper motor end-caps, pump impellers, pneumatic valve blocks, instrument bezels, and automation brackets.
Electrical & Switchgear
Circuit breaker linkages, potentiometer housings, conduit fittings, electrical ground lugs, and high-conductivity terminal bodies.
Strapped Pallet Bundling & Export Logistics
Bhatti Chemicals Industry provides standardized, heavy-duty ingot bundling that facilitates efficient forklift handling, container stuffing, and long-voyage sea transit without surface oxidation.
All export shipments are accompanied by complete documentation including Certificates of Analysis (COA), packing lists, commercial invoices, and optional SGS third-party inspection verification.
Standard Ingot Dimensions
Trapezoidal ingot bars weighing ~10–12 kg each with interlocking self-stacking base contours.
Bundle Configuration
~1,000 kg (1 MT) strapped bundles reinforced with four high-tensile anti-rust steel bands.
Moisture Protection
Heavy-gauge polyethylene shrink-wrapping with desiccant packs to prevent transit oxidation.
Container Freight Logistics
20–25 MT per 20ft FCL dispatched promptly through Karachi / Port Qasim shipping terminals.
Explore Other Bhatti Zinc Chemicals
Supplying world-class zinc compounds and metallic feedstock manufactured under ISO 9001:2015 quality standards.
Zinc Alloy — Frequently Asked Questions
Technical answers to help die casters and procurement managers select the ideal zinc alloy grade.
We supply standard ZAMAK 3, ZAMAK 5, and ZAMAK 7 grades conforming strictly to ASTM B240 and EN 12844 specifications. Furthermore, our induction melting foundry can produce customized zinc alloy master heats tailored to specific aluminium, copper, or magnesium requirements.
All alloys are produced exclusively from 99.99% Special High Grade (SHG) base zinc metal. Controlling residual tin, lead, and cadmium below 0.005% is critical in zinc die casting to prevent intergranular stress corrosion cracking over prolonged operating lifespans.
Choose ZAMAK 3 if your part requires maximum long-term dimensional stability, high ductility for secondary forming/crimping, or extensive electroplating (mirror chrome, satin nickel). Choose ZAMAK 5 if the casting requires ~15% higher tensile strength (330 MPa) and increased wear resistance, such as automotive transmission levers, gear components, and heavy-duty locks.
ZAMAK 7 features a reduced magnesium ceiling (0.005–0.020%) and a minute nickel addition that dramatically lowers melt surface tension. This provides superior fluidity, allowing casters to fill intricate wall sections down to 0.6 mm while maintaining maximum ductility (13% elongation) for post-cast assembly.
Each batch is sampled and analyzed via Optical Emission Spectrometry (OES) across 12 elements to verify tight compliance with ASTM B240 chemistry. Mechanical tensile and hardness checks are performed on representative test bars. Full analytical Certificates of Analysis (COA) accompany every dispatch.
You can contact our commercial trade desk directly via WhatsApp at +92 304 1462460 or email info@bhattichemicalsindustry.com.pk. State your desired alloy grade, required monthly or spot tonnage, and preferred Incoterm (FOB Karachi, CIF destination port).
Source Certified Zinc Alloy Ingots
Competitive global pricing, dependable chemistry guarantees, and rapid containerized shipping from Karachi.