1. Zinc Alloys
Common grades: Zamak 3, Zamak 5, Zamak 7, ZA-8 Key properties
Excellent fluidity, ultra-thin wall casting capability
High dimensional stability, easy plating, polishing & surface finishing
Good ductility, low melting temperature; lower tool wear
Lower tensile strength compared with aluminum alloys Best use cases
Small complex consumer hardware, locks, hinges, decorative trim
Electronic housings, connectors, toy parts
Components requiring chrome plating or high cosmetic surface
Low-to-medium temperature working environments Limitations: Not for high-temperature service; heavier than aluminum
2. Aluminum Alloys
Common grades: A380, A413, A356, ADC10, ADC12 Key properties
Lightweight, high strength-to-weight ratio
Good corrosion resistance, excellent thermal conductivity
High operating temperature tolerance
Lower density, cost-effective for medium-to-large parts Best use cases
Automotive components: engine brackets, transmission housings, heat sinks
LED lighting housings, electronic enclosures
Structural parts requiring heat dissipation
EV battery casings, motor housings Limitations: Higher melting point; more abrasive to dies; hard to plate directly
3. Magnesium Alloys
Common grades: AZ91D, AM60B Key properties
Lightest mainstream die casting alloy
Outstanding vibration damping, high stiffness
Easy machining; good electromagnetic shielding Best use cases
Portable electronics: laptop frames, camera bodies
Automotive lightweight structural parts
Handheld power tool housings Limitations: Poor corrosion resistance without coating; higher material cost; strict process safety requirements
4. Copper Alloys
Common grades: Brass, bronze die casting alloys Key properties
Superior electrical & thermal conductivity
High wear resistance, corrosion resistance Best use cases
Electrical contacts, conductive terminals
Valve components, plumbing fittings, bearing parts Limitations: Very high melting temperature, severe die erosion; high raw material cost; only for high-value functional parts
5. Lead & Tin Alloys (low-melting alloy)
Key properties: Extremely low melting point, great fluidity Best use cases: Low-temperature mold casting, decorative ornaments, counterweights Limitations: Heavy, poor mechanical strength; lead-containing alloys restricted by environmental regulations
Quick Selection Guide
| Alloy Family | Primary Advantage | Typical Working Temp | Ideal Application |
|---|---|---|---|
| Zinc | Plating capability, thin walls, low tool cost | <120℃ | Decorative parts, small fittings |
| Aluminum | Lightweight, heat dissipation, strength | Up to 200℃ | Auto parts, heat sinks, enclosures |
| Magnesium | Minimum weight, EMI shielding | <150℃ | Portable lightweight devices |
| Copper | High conductivity & wear resistance | Wide range | Conductive & wear-critical components |
Supplementary Selection Principles
Weight requirement: Prioritize Mg > Al > Zn > Cu
Surface appearance & plating: Zinc alloys are the first choice
Heat dissipation: Aluminum alloys are preferred
Electrical conductivity: Copper > Aluminum > Magnesium > Zinc
Component size & wall thickness: Zinc suits ultra-thin small parts; aluminum for large castings
