What is the Density of Zinc Alloy Die Casting?

　　Zinc alloy die casting typically has a density ranging from approximately 6.6 to 7.2 grams per cubic centimeter (g/cm³), depending on the specific alloy composition. This density is higher than that of aluminum alloys (2.5–2.8 g/cm³) but lower than many ferrous metals like steel (7.85 g/cm³) or copper alloys (8.5–9.0 g/cm³). The primary reason for this density range is the base element—zinc (Zn), which has a pure density of 7.14 g/cm³—and the alloying elements added to improve casting properties, strength, and durability.

　　Common zinc alloys used in die casting, such as Zamak 3, Zamak 5, and Zamak 2, typically contain aluminum (3–4%), magnesium (0.03–0.06%), and copper (up to 3% in Zamak 5). Aluminum lowers the melting point and improves fluidity during casting, while magnesium enhances corrosion resistance and dimensional stability. Copper additions increase tensile strength and hardness but may slightly raise the density due to copper’s higher atomic weight (8.96 g/cm³). For example, Zamak 3, the most widely used zinc alloy for die casting, has a density of around 6.6–6.7 g/cm³, while Zamak 5, with higher copper content, may reach 6.8–7.0 g/cm³.

　　The density of zinc alloys is a critical factor in part design and manufacturing. A higher density means that zinc die castings are heavier than aluminum counterparts of the same volume, which can be a disadvantage in applications requiring lightweight components, such as automotive or aerospace parts. However, the higher density also contributes to better dimensional stability, impact resistance, and mechanical properties at room temperature. Additionally, the density affects material cost and shipping weight, as heavier parts may incur higher transportation costs.

　　In practical applications, engineers must balance density with other properties. For instance, while zinc alloys are denser than aluminum, they offer superior castability, allowing for intricate geometries and thin walls, which can sometimes offset the weight disadvantage through more efficient part design. Moreover, zinc alloys’ lower melting point compared to aluminum or steel reduces energy consumption during casting, making them cost-effective for high-volume production.

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