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

ParameterDetails
Base MetalAluminium
Alloying ElementsSi, Mg, Zn, Cu, Mn, Ni, Fe, Cr
Particle Size10 – 150 microns
Production MethodsGas Atomization, Mechanical Alloying
PropertiesStrength, Wear Resistance, Conductivity
ApplicationsAutomotive, Aerospace, Electronics
aluminium alloys powder

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 FamilyAlloy DesignationsComposition
1xxx Series1350, 137099% Al, Cu
2xxx Series2024, 2219Al-Cu
5xxx Series5052, 5083Al-Mg
6xxx Series6060, 6061, 6063Al-Mg-Si
7xxx Series7050, 7055, 7175Al-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

ParameterDetailsRole
Alloying ElementsMg, Si, Cu, Zn, Ni, etc.Modify strength, hardness, corrosion resistance, conductivity
Particle Size10 – 150 microns typicalAffects densification, finishing
Particle MorphologySpherical, satellite, irregularImpacts flow and packing density
Flow RatesHall flow test > 12 s/50gEnsure 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

PropertyRole and Details
StrengthVaries from 100 – 700 MPa+ based on alloy, heat treatment
HardnessBetween 50 – 200 HB; Increased by alloy selection, quenching
DensityAround 2.7 g/cc
Melting Point500°C – 660°C for common alloys
Thermal ConductivityUp to 200 W/mK, varies by alloy composition
Electrical Conductivity30 – 40% of pure aluminium
Corrosion ResistanceFair, 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

IndustryApplication ExamplesBenefits
AutomotivePistons, connecting rods, gearsLight weighting, some strength
AerospaceStructural and transmission componentsStrength-to-weight ratio
ElectronicsHeat sinks, connectors, encapsulationsThermal management
DefenseGrenades, projectiles, decoysFragmentation, radar confusion
GeneralGearboxes, luggage parts, antennasCorrosion 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/SpecificationDetails
ISO StandardsISO 22068 – Powder sizes <150 μm
ASTM StandardsASTM B951 – Chemical compositions for metal injection molding
Available GradesCustom alloys, 2013, 2024, 2219, 5052, 6061, 7050, 7075
Particle Size DistributionD10, D50, D90 measures in microns
Apparent DensityIn g/cc based on Hall flow meter test
Tap DensityIn g/cc, indicates packing density
Flow RatesHall flow in sec/50 g, avalanche angle
ChemistryAl, 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

ParameterFactors to Consider
Alloy TypeRequired strength, ductility, corrosion resistance, conductivity
Particle Size RangeFinish quality needed, manufacturing method constraints
Particle MorphologyImpact on powder flow rates, density after compaction
Apparent DensityHigher is better for high sintered density
CostPurity, production method (atomization > mechanical alloying)
AvailabilityLonger 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

SupplierIndicative 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.

aluminium alloys powder

Pros and Cons of Aluminium Alloy Powder

Table 9: Advantages and Limitations of Aluminium Alloy Powder

AdvantagesLimitations
Lightweight parts possibleLower strength than steels
Complex, net shape geometries feasibleLimited high temperature properties
Range of alloy choices availablePost-processing often required
MIM cost-effective for medium volumesPowder can be expensive
Good finishing and tolerancesSusceptible 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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