Aluminium Alloys Powder

Aluminium alloys powder refers to powder metallurgy forms of aluminium alloys. This powder can be used to manufacture parts and components through methods like metal injection molding, additive manufacturing, powder compacting, and more.

Overview of Aluminium Alloys Powder

Aluminium alloy powders provide advantages like ability to produce complex shapes, good finishing, and mechanical properties close to forged products. Key details:

• Alloying elements like silicon, magnesium, zinc, copper are added to enhance properties
• Particle size, morphology, flowability are key powder characteristics
• Gas atomization and mechanical alloying are common production methods
• Applications include automotive parts, aircraft components, electronics, etc.

Table 1: Key Details of Aluminium Alloys Powder

Parameter	Details
Base Metal	Aluminium
Alloying Elements	Si, Mg, Zn, Cu, Mn, Ni, Fe, Cr
Particle Size	10 – 150 microns
Production Methods	Gas Atomization, Mechanical Alloying
Properties	Strength, Wear Resistance, Conductivity
Applications	Automotive, Aerospace, Electronics

Types of Aluminium Alloys Powder

Many standardized and customised aluminium alloy powder compositions are available. Common alloy systems include:

Table 2: Major Types of Aluminium Alloys Powder

Alloy Family	Alloy Designations	Composition
1xxx Series	1350, 1370	99% Al, Cu
2xxx Series	2024, 2219	Al-Cu
5xxx Series	5052, 5083	Al-Mg
6xxx Series	6060, 6061, 6063	Al-Mg-Si
7xxx Series	7050, 7055, 7175	Al-Zn

These provide unique balances of corrosion resistance, strength, formability and other properties. Custom alloys tailored for additive manufacturing are also offered.

Composition and Powder Characteristics

Alloying elements, particle size distribution, morphology and flow rates are important powder parameters influencing manufacturing process and final part qualities.

Table 3: Aluminium Alloys Powder Composition and Characteristics

Parameter	Details	Role
Alloying Elements	Mg, Si, Cu, Zn, Ni, etc.	Modify strength, hardness, corrosion resistance, conductivity
Particle Size	10 – 150 microns typical	Affects densification, finishing
Particle Morphology	Spherical, satellite, irregular	Impacts flow and packing density
Flow Rates	Hall flow test > 12 s/50g	Ensure smooth feeding into equipment

Gas atomized aluminium powders have spherical particles beneficial for flow and packing. Irregular shapes from mechanical production lower these metrics but allow economic alloying.

Properties and Performance

Following properties of aluminium alloys powder influence their role and manufacturing method selection:

Table 4: Properties of Aluminium Alloys Powder

Property	Role and Details
Strength	Varies from 100 – 700 MPa+ based on alloy, heat treatment
Hardness	Between 50 – 200 HB; Increased by alloy selection, quenching
Density	Around 2.7 g/cc
Melting Point	500°C – 660°C for common alloys
Thermal Conductivity	Up to 200 W/mK, varies by alloy composition
Electrical Conductivity	30 – 40% of pure aluminium
Corrosion Resistance	Fair, improved by surface treatments
Cost	$5-50 per kg, depends on alloy and atomization method

These represent typical properties – precise values depend on composition, powder size, part geometry and other specifics.

Applications and Uses

Key application areas taking advantage of aluminium alloys powder’s properties:

Table 5: Applications of Aluminium Alloys Powder

Industry	Application Examples	Benefits
Automotive	Pistons, connecting rods, gears	Light weighting, some strength
Aerospace	Structural and transmission components	Strength-to-weight ratio
Electronics	Heat sinks, connectors, encapsulations	Thermal management
Defense	Grenades, projectiles, decoys	Fragmentation, radar confusion
General	Gearboxes, luggage parts, antennas	Corrosion resistance, economy

Aluminium metal injection molding in particular allows affordable medium-to-high volume manufacturing of complex, tight tolerance products across industries.

Specifications, Standards and Grades

Key aluminium alloy powder specifications, sizes and standards include:

Table 6: Specifications and Standards for Aluminium Alloys Powder

Standard/Specification	Details
ISO Standards	ISO 22068 – Powder sizes <150 μm
ASTM Standards	ASTM B951 – Chemical compositions for metal injection molding
Available Grades	Custom alloys, 2013, 2024, 2219, 5052, 6061, 7050, 7075
Particle Size Distribution	D10, D50, D90 measures in microns
Apparent Density	In g/cc based on Hall flow meter test
Tap Density	In g/cc, indicates packing density
Flow Rates	Hall flow in sec/50 g, avalanche angle
Chemistry	Al, Mg, Si, Fe, Cu content in % wt verified

These help define product performance. Conformance certifications to company-specific specifications are also common in supply contracts.

Selecting Aluminium Alloy Powders

Consider these aspects when selecting appropriate grade:

Table 7: Criteria for Selecting Aluminium Alloys Powder

Parameter	Factors to Consider
Alloy Type	Required strength, ductility, corrosion resistance, conductivity
Particle Size Range	Finish quality needed, manufacturing method constraints
Particle Morphology	Impact on powder flow rates, density after compaction
Apparent Density	Higher is better for high sintered density
Cost	Purity, production method (atomization > mechanical alloying)
Availability	Longer lead times for custom alloys

Balance performance needs like strength and corrosion resistance against cost, availability and manufacturability considerations.

Suppliers and Pricing

A range of global specialty metal powder suppliers offer aluminium alloys:

Table 8: Aluminium Alloy Powder Suppliers and Indicative Pricing

Supplier	Indicative Pricing
Sandvik	$5 – $15 per kg
Pometon	$10 – $40 per kg
Carpenter Additive	$15 – $50 per kg
AP&C	$25 – $45 per kg
Rio Tinto Metal Powders	$20 – $60 per kg

Large volume OEM contracts attract far lower rates. Prices depend on order volumes, alloy composition, atomization method and purity levels.

Pros and Cons of Aluminium Alloy Powder

Table 9: Advantages and Limitations of Aluminium Alloy Powder

Advantages	Limitations
Lightweight parts possible	Lower strength than steels
Complex, net shape geometries feasible	Limited high temperature properties
Range of alloy choices available	Post-processing often required
MIM cost-effective for medium volumes	Powder can be expensive
Good finishing and tolerances	Susceptible to corrosion in some alloys

FAQs

Q: What are the most common aluminium alloys for powder metallurgy?

A: 6061, 6063, 7075 are most popular but many customized alloys optimized for additive manufacturing and metal injection molding are also used.

Q: Does aluminium alloy powder require special storage or handling precautions?

A: Inert gas blanketing and cool, dry storage is recommended. Handling systems should prevent ignition of fine powders.

Q: What particle size is best suited for metal AM vs injection molding of aluminium alloys?

A: Metal AM generally uses 20-65 microns while MIM aluminium powders are typically around 10-25 microns.

Q: What post-processing heat treatments are performed on aluminium MIM components?

A: Solution treatment, aging/precipitation hardening, quenching and tempering are often used depending on the alloy and properties needed.

Q: Is aluminium alloy powder reusable through reconditioning?

A: Yes, companies offer reconditioning and sieving services to salvage used powder for reuse. But properties may not be identical to virgin powder.

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