3D Printing Aluminum Alloys

Table of Contents

3d printing aluminum alloys offer several beneficial characteristics like high strength-to-weight ratio, excellent thermal conductivity, and corrosion resistance that make them suitable materials for 3D printing applications across automotive, aerospace, consumer goods, and other industries.

Selective laser melting (SLM) and direct metal laser sintering (DMLS) are the primary 3D printing processes used for aluminum alloy powders. The powders particles are fused together layer-by-layer using a high power laser to construct complex and customizable component geometries.

3d printing aluminum alloys

Types of 3d printing aluminum alloys

AlloyCompositionPrinting ProcessPropertiesApplications
AlSi10MgAluminum (Al) + Silicon (Si) (10%) + Magnesium (Mg)Laser Powder Bed Fusion (LPBF)• Good balance of strength, ductility, and toughness • Excellent weldability • Age-hardenable for increased strength• Aerospace components (lightweight structures) • Automotive parts (brackets, engine components) • Electronic packaging
AlSi7Mg (F357)Aluminum (Al) + Silicon (Si) (7%) + Magnesium (Mg)LPBF• Similar properties to AlSi10Mg, but slightly lower strength • Easier to print due to lower melting point• General purpose applications requiring good strength-to-weight ratio • Fluid handling components • Brackets and housings
Al2139Aluminum (Al) + Copper (Cu) (4%) + Magnesium (Mg)LPBF• High strength and fatigue resistance • Good machinability• Aerospace components requiring high strength • Automotive parts (suspension components)
6061Aluminum (Al) + Magnesium (Mg) (0.9%) + Silicon (Si) (0.6%) + Copper (Cu) (0.3%)LPBF (limited), Binder Jetting (BJ)• Excellent corrosion resistance • Good machinability and weldability • Moderate strength• Prototypes and functional parts requiring good all-around properties • Architectural components • Heat sinks
7075Aluminum (Al) + Zinc (Zn) (5.6%) + Magnesium (Mg) (2.5%) + Copper (Cu) (1.6%)LPBF (limited), Electron Beam Melting (EBM)• Very high strength-to-weight ratio • Excellent wear resistance • Not weldable• Aerospace components requiring high strength and low weight • Sporting goods (bicycle frames, baseball bats)
ScalmalloyAluminum (Al) + Scandium (Sc) (4%) + Magnesium (Mg) (6%)LPBF• Exceptional strength-to-weight ratio, exceeding 7075 • Excellent corrosion resistance • High crack resistance• High-performance aerospace components • Defense applications requiring lightweight armor

Composition of 3d printing aluminum alloys

Alloy DesignationPrimary Alloying ElementsAdditional ElementsPropertiesApplications
AlSi10MgSilicon (10%)Magnesium (0.3-0.5%)* Excellent castability (adapted from casting applications) * Good weldability * High strength and toughness * Good corrosion resistance* General purpose applications * Automotive components * Aerospace components (non-critical) * Brackets and housings *
AlSi7Mg (F357)Silicon (7%)Magnesium (0.3-0.5%)* Similar properties to AlSi10Mg, but slightly lower strength * Excellent castability * Good weldability * Good corrosion resistance* Similar applications to AlSi10Mg, often used when a bit lower weight is desired * Engine components * Fluid handling components
AlSi12Silicon (12%)* High strength and wear resistance * Good castability * Moderate weldability * Lower corrosion resistance compared to AlSi10Mg and F357* Wear plates * Gears * Sand casting applications (often used as a starting point for 3D printed parts due to familiarity with the material)
ScalmalloyScandium (4.0-4.4%)Magnesium (0.3-0.5%)* Exceptional strength-to-weight ratio * Excellent corrosion resistance * Good weldability * Requires heat treatment for optimal properties* Aerospace components (high-performance) * Automotive components (weight critical) * Defense applications
EOS Aluminium Al2139 AMNot publicly disclosed (likely Aluminum-Magnesium-Silicon)* Developed specifically for additive manufacturing * Good strength at elevated temperatures (up to 200°C) * Improved processability compared to standard casting alloys * Requires heat treatment for optimal properties* Aerospace components requiring high-temperature performance * Automotive components * Heat exchanger components

Characteristics of 3D Printable Aluminum

AttributeDetails
Surface FinishPowder adhesion can leave semi-rough, stepped surface profile
AccuracyGenerally high dimensional accuracy up to ±0.1% is possible
AnisotropyDirectionally weaker mechanical properties observed
Porosity<1% porosity achieved under optimized SLM parameters
Alloy FlexibilityMany 2xxx, 5xxx, 6xxx, and 7xxx grades printable

Applications of 3d printing aluminum alloys

IndustryTypical Applications
AerospaceAircraft ductwork, heat exchangers, structural brackets
AutomotiveCustom brackets, supports, heat sinks, tooling
ArchitectureLightweight panels, decorative lattices, small sculptures
MedicalFirmware like surgical instruments, implants
ElectronicsHeat dissipation devices like heat sinks
DefenseLow volume parts with reduced lead times

Aluminum Powder Specifications for Additive Manufacturing

ParameterType/Range
MaterialsAlSi10Mg, AlSi7Mg0.6, AlSi12, AlSi9Cu3
Particle size25 to 65 microns
Particle shapeMostly spherical, some satellites allowed
Apparent densityAround 2.67 g/cc
Flow rate<30 s/50 g per ASTM B964
Residual oxygen<0.4% for high tensile strength

Leading Suppliers of 3d printing aluminum alloys

SupplierSpecialtyKey ProductsApplicationsAdditional Services
Elementum 3DInnovative PowdersGas-atomized aluminum alloy powders, including traditional and dispersion-strengthened variantsAerospace, automotive, defenseMaterial development, application engineering, printing parameter optimization
APWorksHigh-Performance AlloysScalable Aluminum Silicon Magnesium (AlSiMg) alloy for Laser Beam Melting (LBM)Automotive components, robotics, industrial machineryDesign for Additive Manufacturing (DFAM) consulting, post-processing services
SLM SolutionsEstablished ManufacturerAluminum alloys optimized for Selective Laser Melting (SLM) process, including AlSi10Mg and ScalmalloyMedical implants, aerospace components, heat exchangersMachine sales and support, parameter development for specific alloys
EOS GmbHMulti-Process CompatibilityAluminum alloys compatible with both Laser Beam Melting (LBM) and Electron Beam Melting (EBM) technologiesAerospace parts, consumer electronics, medical devicesConsulting on machine selection and process optimization, training programs
HöganäsMetal Powder ExpertiseGas-atomized aluminum powders with tight size and morphology controlHeat exchangers, automotive components, electronics enclosuresPowder characterization and testing, collaboration on new alloy development
Royal AlloyDiverse Alloy PortfolioWide range of aluminum alloy powders, including scandium and lithium additions for enhanced performanceAerospace components, defense applications, high-performance heat sinksMaterial selection guidance, printability testing, custom powder development
Norsk HydroSustainable ProductionAluminum alloy powders produced with a focus on minimal environmental impactAutomotive parts, architectural components, consumer electronicsLife cycle assessment (LCA) data for materials, support for sustainable manufacturing practices
ExOneBinder Jetting TechnologyAluminum alloys specifically formulated for binder jetting additive manufacturing (BJAM)Automotive prototypes, sand casting molds, industrial toolingDesign for Additive Manufacturing (DFAM) services, post-processing expertise for BJAM parts
DMG Mori SeikiIntegrated SolutionsAluminum alloy powders alongside compatible metal 3D printersTooling and molds, medical implants, aerospace componentsMachine sales and service, training on metal additive manufacturing workflows
Carpenter Additive ManufacturingSpecialty AlloysAluminum alloys with high strength-to-weight ratios and improved corrosion resistanceMarine components, oil and gas equipment, chemical processing applicationsMaterial selection support, application engineering services, prototyping assistance

Pros and Cons of 3D Printed Aluminum

FeatureProsCons
Design FreedomUnmatched Complexity: Allows for intricate lattice structures, internal channels, and lightweighting features impossible with traditional methods. Enables designers to push boundaries and create high-performance parts.
Rapid Prototyping: Enables quick iteration and testing of designs, reducing development time and cost.
Support Structures: Complex geometries often require intricate support structures, adding post-processing time and potentially creating unwanted surface textures.
Material PropertiesExcellent Strength-to-Weight Ratio: Aluminum offers a good balance between weight and strength, making it ideal for applications like aerospace and automotive where weight reduction is crucial.
Corrosion Resistance: Many aluminum alloys boast excellent resistance to corrosion, particularly valuable for parts exposed to harsh environments.
Anisotropy: The layered nature of 3D printing can lead to anisotropic properties, meaning the strength of the material can vary depending on the printing direction. This may require design adjustments for certain applications.
Porosity: Depending on the printing process, small voids or pores can be present within the material, potentially impacting mechanical properties. Post-processing techniques like hot isostatic pressing (HIP) can mitigate this.
ManufacturingReduced Lead Time: 3D printing allows for on-demand production, eliminating the need for complex tooling and minimizing lead times for prototypes or low-volume parts.
Minimal Material Waste: The additive nature of 3D printing significantly reduces material waste compared to traditional subtractive manufacturing methods.
High Cost: The technology and equipment for 3D printing aluminum are still relatively expensive, making it less cost-effective for high-volume production compared to traditional methods.
Build Time: Printing complex metal parts can be time-consuming, impacting overall production speed.
Post-ProcessingSurface Finish: While some 3D printing technologies offer good surface finishes, roughness is a common concern. Post-processing techniques like machining, polishing, or sandblasting may be necessary for certain applications.
Heat Treatment: Specific aluminum alloys may require heat treatment after printing to achieve optimal mechanical properties.
Additional Cost and Time: Post-processing adds to the overall production time and cost of the part.
ApplicationsAerospace: The ability to create lightweight, high-strength components with complex geometries makes 3D printed aluminum ideal for aerospace applications like heat exchangers, brackets, and structural components.
Automotive: Weight reduction is a major concern in the automotive industry. 3D printed aluminum components can be used for parts like wheels, engine components, and lightweight chassis structures.
Medical: Biocompatible aluminum alloys can be used to create custom prosthetics and implants.
Limited Applications for High-Stress Components: Due to potential anisotropy and porosity, 3D printed aluminum may not be suitable for all high-stress applications. Careful design and material selection are crucial.
3d printing aluminum alloys

FAQ

Q: Which aluminum alloy is best suited for additive manufacturing?

A: AlSi10Mg is the most widely adopted aluminum alloy offering a good combination of fluidity, strength, hardness and corrosion resistance combined with compatibility across various printers.

Q: Does build orientation affect properties of 3D printed aluminum components?

A: Yes, building vertically can exhibit 20-30% lower tensile and yield strengths versus horizontally built parts due to layer-by-layer construction. Mechanical performance also varies depending on loading parallel or perpendicular to layers.

Q: What solution heat treatments can enhance aluminum properties?

A: T6 heat treatment (solubilize then artificially age harden) of some additively manufactured alloys like AlSi10Mg can significantly increase tensile strength, hardness and ductility compared to as-built state.

Q: How are surface finishes improved for additively made aluminum parts?

A: Various finishing procedures like sand blasting, bead blasting, laser polishing, CNC machining, grinding or linishing can help smooth out the stepped contours typically observed on as-built aluminum surfaces from powder-based printing.

Q: Does aluminum powder reuse affect 3D printed part properties?

A: Recycling aluminum build powder upto 10-20 times typically does not impact mechanical performance. But beyond around 25 reuse cycles, declining powder flowability, lower density, and higher oxygen/nitride impurities can start deteriorating material quality and strengths.

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