Magnesium Alloy AZ91D Powder
AZ91D Powder is a gas-atomized magnesium powder to AZ91D (Mg-Al-Zn) chemistry for laser powder-bed fusion and binder jetting, available as POWDER, AB, SR, T4, T6, HIP and BJT-SINT conditions.
Reference datasheet — AZ91D Powder is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the AB condition
AZ91D Powder tempers and conditions
AZ91D Powder is supplied in 6 conditions, soft to hard. AB is the default FabDigit quotes; the values on this page are for it.
Compare all 6 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
binder jetted and sintered | Pick only for low-stress, complex-geometry demonstrators — residual porosity of 5–15 % caps strength and worsens corrosion. | 90 | 120 | 1 | 55 HB | 9 % IACS |
Solution heat treated and naturally aged | Pick for maximum ductility and impact toughness: the β-Mg17Al12 network is dissolved, yield strength drops sharply. | 105 | 265 | 10 | 55 HB | 10.5 % IACS |
Hot isostatic pressed | Pick for fatigue- or pressure-critical printed parts where internal gas porosity and lack-of-fusion defects must be closed. | 150 | 280 | 7 | 68 HB | 13 % IACS |
Solution heat treated and artificially aged | Pick for the best strength/ductility balance in a homogenized, low-residual-stress printed part. | 160 | 285 | 5 | 72 HB | 12.5 % IACS |
Stress relieved | Pick when printed parts must be removed from the plate or machined without distortion; small strength loss, slightly better ductility. | 220 | 275 | 3.5 | 70 HB | 12.5 % IACS |
ABDefault As built (as printed) | Default condition for printed AZ91D parts: fine rapidly-solidified microstructure gives the highest yield strength but retains high residual stress. | 245 | 290 | 2.5 | 75 HB | 51 W/m·K |
Supply forms, finishes and certifications
Ways AZ91D Powder is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
POWDER | Gas-atomized, as-supplied | Printing process |
What is AZ91D Powder?
AZ91D Powder is a gas-atomized magnesium powder to AZ91D (Mg-Al-Zn) chemistry for laser powder-bed fusion and binder jetting, available as POWDER, AB, SR, T4, T6, HIP and BJT-SINT conditions. It is chosen when the lowest-density printable structural metal is needed, giving default values of 245 MPa yield, 290 MPa tensile, 2.5 % elongation, 75 HB and 51 W/m·K thermal conductivity. Limits are low ductility, a 120 °C service ceiling and a corrosion resistance score of 25, so coating is mandatory. Processing also demands inert powder handling and Class D fire precautions. AZ91D Powder has a density of 1.81 g/cm³ (0.0654 lb/in³), heavier than 58% of magnesium alloy grades. It melts at 470°C (878 °F). AZ91D Powder has a yield strength of 245 MPa (35.5 ksi) and a tensile strength of 290 MPa (42.1 ksi) — stronger than 96% of magnesium alloy grades. Elongation at break is 2.5% and the elastic modulus is 45 GPa (6.53 Msi).
What is AZ91D Powder used for?
- 3D-printed lightweight brackets
- biomedical scaffolds
- prototype magnesium parts
Advantages
- High strength — 245 MPa (35.5 ksi), better than 96% of magnesium alloy grades
Limitations
- Limited ductility — 2.5%, worse than 97% of magnesium alloy grades
- Poor heat conductor — 51 W/m·K (29.5 BTU/hr·ft·°F), worse than 97% of magnesium alloy grades
- Low fracture toughness — 12 MPa·√m (10.9 ksi·√in), worse than 92% of magnesium alloy grades
- Limited service temperature — 120°C (248 °F), worse than 78% of magnesium alloy grades
- Low electrical conductivity — 12 % IACS, worse than 78% of magnesium alloy grades
AZ91D Powder properties
Typical room-temperature values for AZ91D Powder-AB; bars are the position among magnesium alloy grades.
Physical3
AZ91D Powder has a density of 1.81 g/cm³ (0.0654 lb/in³), heavier than 58% of magnesium alloy grades. It melts at 470°C (878 °F).
Mechanical14
AZ91D Powder has a yield strength of 245 MPa (35.5 ksi) and a tensile strength of 290 MPa (42.1 ksi) — stronger than 96% of magnesium alloy grades. Elongation at break is 2.5% and the elastic modulus is 45 GPa (6.53 Msi).
Thermal6
AZ91D Powder is rated for continuous service to 120°C (248 °F). It conducts heat at 51 W/m·K (29.5 BTU/hr·ft·°F), worse than 97% of magnesium alloy grades. Thermal expansion is 26 µm/m·K (14.4 µin/in·°F).
Electrical3
AZ91D Powder conducts electricity at 12 % IACS, worse than 78% of magnesium alloy grades.
Chemical & Environmental3
Corrosion resistance is poor (25/100), better than 64% of magnesium alloy grades.
Sustainability4
Producing a kilogram of AZ91D Powder takes about 375 MJ of energy and emits 32 kg of CO₂ — more than 90% of magnesium alloy grades. Typical recycled content is 5%.
Manufacturability7
AZ91D Powder's machinability is excellent (95/100, better than 54% of magnesium alloy grades); weldability good (60/100); formability poor (15/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the magnesium alloy family
Yield strength against density for every magnesium alloy grade FabDigit runs. AZ91D Powder is highlighted; hover a dot for its name, or open the interactive family chart.
Working with AZ91D Powder
Is AZ91D Powder easy to machine?
Cuts extremely easily with sharp, high-rake carbide tools and high speeds, but chips and fine dust ignite readily — use dry or mineral-oil cutting (never water-based), keep chips wet-free and have Class D extinguishing media at the machine.
Can AZ91D Powder be welded?
Printed AZ91D is GTAW/GMAW weldable with AZ92A filler under argon; preheat lightly, expect porosity from entrapped process gas and hot-cracking near the Mg17Al12 network.
Can AZ91D Powder be formed, bent or molded?
L-PBF requires strictly inert (Ar, <100 ppm O2) build atmosphere, wet-separator filtration and vacuum/inert powder handling; low laser energy and thin layers (20–30 µm) limit Mg and Zn evaporation and spatter.
AZ91D Powder chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Al | 8.5 – 9.5 | 9 |
| Zn | 0.45 – 0.9 | 0.7 |
| Mn | 0.17 – 0.4 | 0.25 |
| Si | ≤ 0.05 | |
| Cu | ≤ 0.03 | |
| Ni | ≤ 0 | |
| Fehigh-purity limit; Fe/Mn ratio ≤ 0.032 | ≤ 0 | |
| Bemelt-protection addition, typical 5–15 ppm | ≤ 0 | |
| Others (each) | ≤ 0.01 | |
| Others (total) | ≤ 0.02 | |
| Otypical atomized-powder oxygen pickup, not in ASTM B93 | ≤ 0.05 | 0.02 |
| Mg | balance |
What surface finishes work on AZ91D Powder?
Never leave bare: apply chromate-free conversion coating, HAE/Dow-17 or plasma electrolytic oxidation plus an organic topcoat, and electrically isolate all steel/aluminium fasteners to avoid galvanic attack.
How much does AZ91D Powder cost?
AZ91D Powder is a high-cost magnesium alloy ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
AZ91D Powder — frequently asked
What is AZ91D Powder used for?
AZ91D Powder is typically used for 3D-printed lightweight brackets, biomedical scaffolds and prototype magnesium parts. In short: lowest-density printable metal; established Mg AM chemistry; needs inert powder handling.
What is the yield strength of AZ91D Powder?
AZ91D Powder has a typical yield strength of 245 MPa (35.5 ksi) and a tensile strength of 290 MPa (42.1 ksi) — stronger than 96% of magnesium alloy grades. Strength varies by condition: see the 6 listed tempers.
Is AZ91D Powder easy to machine?
Yes — machinability is rated excellent (95/100, better than 54% of magnesium alloy grades). Cuts extremely easily with sharp, high-rake carbide tools and high speeds, but chips and fine dust ignite readily — use dry or mineral-oil cutting (never water-based), keep chips wet-free and have Class D extinguishing media at the machine.
Can AZ91D Powder be welded?
Yes — weldability is rated good (60/100). Printed AZ91D is GTAW/GMAW weldable with AZ92A filler under argon; preheat lightly, expect porosity from entrapped process gas and hot-cracking near the Mg17Al12 network.
What surface finishes work on AZ91D Powder?
Never leave bare: apply chromate-free conversion coating, HAE/Dow-17 or plasma electrolytic oxidation plus an organic topcoat, and electrically isolate all steel/aluminium fasteners to avoid galvanic attack.
Can AZ91D Powder be formed, bent or molded?
L-PBF requires strictly inert (Ar, <100 ppm O2) build atmosphere, wet-separator filtration and vacuum/inert powder handling; low laser energy and thin layers (20–30 µm) limit Mg and Zn evaporation and spatter.
What is the maximum service temperature of AZ91D Powder?
AZ91D Powder is rated for continuous use to about 120°C (248 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between AZ91D Powder-AB and AZ91D Powder-T4?
AB is the default condition — default condition for printed AZ91D parts: fine rapidly-solidified microstructure gives the highest yield strength but retains high residual stress. T4: pick for maximum ductility and impact toughness: the β-Mg17Al12 network is dissolved, yield strength drops sharply. Yield strength is 245 MPa in AB versus 105 MPa in T4.
How much does AZ91D Powder cost?
AZ91D Powder is a high-cost magnesium alloy ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- ASTM B93/B93M — Magnesium Alloys in Ingot Form for Sand, Permanent Mold and Die Castings — ASTM International (2020)
- ASTM B94 — Magnesium-Alloy Die Castings — ASTM International (2018)
- ASM Handbook Vol. 2 — Properties and Selection: Nonferrous Alloys and Special-Purpose Materials — ASM International (1990)
- ASM Specialty Handbook: Magnesium and Magnesium Alloys — ASM International (1999)
- GB/T 19078 — (AZ91D) — SAC (2016)
- Published L-PBF AZ91D process-property studies (SLM density, tensile and hardness data) — peer-reviewed AM literature (2022)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.