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A practical engineering reference for selecting aluminum and zinc die casting alloys for custom die casting projects, including chemical composition, mechanical properties, physical characteristics, and international grade comparisons.
Choosing the right alloy impacts not only structural strength and corrosion resistance, but also manufacturing cost, tooling longevity, and surface finishing possibilities.
Weight & Structural Efficiency: High strength-to-weight ratios required for automotive, structural enclosures, and industrial components.
Thermal Management: Excellent thermal conductivity critical for LED lighting housings, heat sinks, and motor enclosures.
Surface Finishing & Precision: Superior castability for intricate lock mechanisms, decorative hardware, and electroplated components.
At RuiYu, we help customers select suitable alloys based on part function, production requirements, surface finishing needs, and cost considerations.
Aluminum alloys are widely used in die casting because of their excellent strength-to-weight ratio, thermal conductivity, corrosion resistance, and manufacturing efficiency.
Al-Si alloys form the backbone of the die casting industry due to their exceptional casting fluidity, low shrinkage, and versatile mechanical balance.
| Alloy Grade | Common Equivalent Grades | Silicon (Si) | Copper (Cu) | Magnesium (Mg) | Iron (Fe) | Zinc (Zn) |
| ADC12 | YL113 / A383 | 9.6 – 12.0 | 1.5 – 3.5 | ≤ 0.30 | ≤ 1.30 | ≤ 1.00 |
| ADC10 | YL112 / A380 | 7.5 – 9.5 | 2.0 – 4.0 | ≤ 0.30 | ≤ 1.30 | ≤ 1.00 |
| ADC3 | YL102 / A360 | 9.5 – 11.5 | ≤ 0.60 | 0.40 – 0.60 | ≤ 1.30 | ≤ 0.50 |
| ADC1 | YL104 / A413 | 11.0 – 13.0 | ≤ 0.60 | ≤ 0 |
Note: These comparisons are commonly referenced in global sourcing. Exact specifications should be confirmed according to the applicable JIS, GB, ASTM, or EN standards.
ADC12 / YL113: ADC12 is one of the most widely used aluminum die casting alloys due to its excellent fluidity, dimensional stability, and cost efficiency. It is commonly used for motor housings, lighting components, and industrial parts.
A380 / YL112: A380 provides a good balance of strength, corrosion resistance, and pressure tightness, making it suitable for automotive and structural components.
ADC3 / YL102: ADC3 provides improved corrosion resistance and pressure tightness, making it suitable for outdoor applications and fluid-related components.
Aluminum-magnesium alloys (ADC5 / ADC6) are specialized die casting materials known for exceptional corrosion resistance, superior toughness, and excellent anodizing properties compared to conventional Al-Si alloys.
| Alloy Grade | Common Reference | Silicon (Si) | Magnesium (Mg) | Copper (Cu) | Iron (Fe) | Zinc (Zn) |
| ADC5 | JIS ADC5 | ≤ 0.30 | 4.0 – 5.5 | ≤ 0.10 | ≤ 1.00 | ≤ 0.30 |
| ADC6 | JIS ADC6 | ≤ 0.10 | 2.5 – 4.0 | ≤ 0.10 |
Exceptional Corrosion Resistance: High magnesium content provides outstanding protection against harsh atmospheric, alkaline, and marine environments. Ideal for outdoor hardware, marine fittings, and heavy-duty valve housings.
Higher Ductility & Toughness: Compared to traditional Al-Si alloys, Al-Mg alloys deliver superior impact resistance and elongation, making them suitable for structural brackets and load-bearing applications.
Design & Process Considerations: Due to lower silicon content, ADC5 and ADC6 exhibit reduced casting fluidity and a narrower processing window. They are generally recommended for relatively simple geometries, moderate wall thicknesses, and carefully engineered tooling designs.
Zinc die casting is widely used for locks, handles, and precision hardware components requiring excellent surface finishing.
Excellent Surface Finish: Ideal for mirror polishing, electroplating (chrome, nickel, satin, gold), and decorative powder coating.
High Dimensional Accuracy & Tight Tolerances: Highly suited for lock cylinders, door handles, cabinet hardware, and micro-precision mechanisms.
Complex Geometry Capability: Exceptional fluidity allows ultra-thin wall sections, complex internal threads, and extended mold tool life.
| Alloy Grade | Common Equivalent | Aluminum (Al) | Copper (Cu) | Magnesium (Mg) | Zinc (Zn) |
| ZDC2 | Zamak 3 / ZX03 | 3.5 – 4.3 | ≤ 0.10 | 0.02 – 0.06 | Balance |
| ZDC1 | Zamak 5 / ZX05 | 3.5 – 4.3 | 0.75 – 1.25 | 0.03 – 0.08 | Balance |
| ZA-8 | ZX08 | 8.0 – 8.8 | 0.80 – 1.30 |
Mechanical properties depend on alloy composition, casting parameters, part geometry, and testing conditions.
| Alloy | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) | Hardness (HBW) |
| ADC12 / A383 | 235 – 310 | ≥ 150 | 1.5 – 3.5 | 75 |
| ADC10 / A380 | 230 – 320 | ≥ 150 | 1.5 – 3.5 | 75 |
| ADC3 / A360 | 220 – 310 | ≥ 140 | 2.0 – 3.5 | 65 |
| ADC1 / A413 | 210 – 290 | ≥ 130 | 1.0 – 2.5 | 60 |
| Alloy | Tensile Strength (MPa) | Impact Energy (J/cm²) | Elongation (%) | Hardness (HBW) |
| ZDC2 / Zamak 3 | ≥ 280 | ≥ 50 | ≥ 10.0 | 80 |
| ZDC1 / Zamak 5 | ≥ 330 | ≥ 40 | ≥ 7.0 | 90 |
| ZA-8 | ≥ 370 | ≥ 35 | ≥ 6.0 |
Physical characteristics are critical when selecting materials for thermal management (LED/Motors) or aggressive environments (Outdoor/Marine).
| Alloy | Density (g/cm³) | Thermal Conductivity (W/m·K) | Corrosion Resistance | Machinability | Surface Finishing Capability |
| ADC12 | 2.74 | 96.2 | Good | Good | E-coating, Powder Coating |
| ADC10 | 2.74 | 96.2 | Good | Excellent | E-coating, Powder Coating |
| ADC3 | 2.63 | 113.0 | Excellent | Fair | Powder Coating, Anodizing |
| ADC5 / 6 | 2.64 | 96.0 – 100.0 | Superior (Marine) | Fair | Anodizing, Clear Coating |
| Zamak 3 | 6.60 | 113.0 | Good | Excellent | Superior Electroplating (Chrome/Nickel) |
| Zamak 5 | 6.70 | 108.9 | Good | Excellent | Superior Electroplating & Painting |
Commonly referenced designations in global sourcing:
| China (GB/T) | Japan (JIS) | USA (ASTM) | Europe (EN) | Key Characteristics |
| YL113 | ADC12 | A383 | EN AC-46100 | Excellent fluid filling for thin-walled complex parts. |
| YL112 | ADC10 | A380 | EN AC-46000 | Universal workhorse alloy; best strength-to-cost ratio. |
| YL102 | ADC3 | A360 | EN AC-44300 | Superior corrosion resistance and pressure tightness. |
| YL302 / YL301 | ADC5 / ADC6 | 518.0 / 515.0 | EN AC-51400 | Maximum corrosion resistance, marine grade, high toughness. |
| ZnAl4 (3# Zinc) | ZDC2 | Zamak 3 | ZP3 (ZnAl4) | Dimensional stability; industry standard for zinc hardware & locks. |
| ZnAl4Cu1 (5# Zinc) | ZDC1 | Zamak 5 | ZP5 (ZnAl4Cu1) | Higher hardness and wear resistance with 1% Cu addition. |
Use this quick-reference matrix to align your functional product requirements with the recommended alloy:
| Engineering / Product Requirement | Recommended Material | Primary Selection Driver |
| Heat Dissipation Enclosures | ADC12 / ADC10 | High thermal conductivity & thin-wall castability |
| Outdoor Lighting & Marine Valve Bodies | ADC3 (A360) | High corrosion resistance & pressure tightness |
| Marine Environment & Harsh Chemical Exposure | ADC5 / ADC6 | Superior salt-spray resistance & impact toughness |
| Precision Lock Components & Mechanisms | Zamak 3 / Zamak 5 | High dimensional stability & structural strength |
| Electroplated Hardware & Decorative Parts | Zamak 3 | Flawless surface finish suitable for chrome plating |
| High-Load Mechanical Components | ADC10 / Zamak 5 | Superior yield strength and wear resistance |
| Cost-Effective High-Volume Parts | ADC12 / ADC10 | Globally available raw material & high processing efficiency |
| Premium Appearance Hardware | Zamak 3 | Excellent mold replication & high-end plating acceptance |
After selecting the right alloy, our engineering team evaluates casting feasibility, tooling design, and production requirements.
Explore our manufacturing capabilities and tailored component solutions:
Custom Aluminum Die Casting: High-precision aluminum components for motor housings, lighting fixtures, structural brackets, and automotive enclosures.
Zinc Precision Die Casting: Tight-tolerance zinc components specialized for locks, trailer locks, and architectural hardware.
Surface Finishing & Post-Processing: Professional surface solutions including electroplating, powder coating, e-coating, anodizing, and precision CNC machining.
Share your product drawings, application requirements, or existing material specifications. Our engineering team can help evaluate alloy selection, casting feasibility, and cost-optimized manufacturing solutions.