Magnesium Alloy AZ91D Powder BJT-SINT
Print state
Pick only for low-stress, complex-geometry demonstrators — residual porosity of 5–15 % caps strength and worsens corrosion.
Values for the BJT-SINT condition
Other AZ91D Powder tempers and conditions
AZ91D Powder is listed in 6 conditions; see the grade overview at AZ91D Powder.
Compare all 6 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
BJT-SINTThis page 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 |
What is AZ91D Powder BJT-SINT?
AZ91D Powder BJT-SINT is AZ91D Powder in the BJT-SINT condition — pick only for low-stress, complex-geometry demonstrators — residual porosity of 5–15 % caps strength and worsens corrosion. AZ91D Powder BJT-SINT has a yield strength of 90 MPa (13.1 ksi) and a tensile strength of 120 MPa (17.4 ksi) — weaker than 96% of magnesium alloy grades. Elongation at break is 1% and the elastic modulus is 35 GPa (5.08 Msi). AZ91D Powder BJT-SINT has a density of 1.65 g/cm³ (0.0596 lb/in³), lighter than 99% of magnesium alloy grades. It melts at 470°C (878 °F). AB is the default condition FabDigit quotes; BJT-SINT is available on request or by drawing note.
Limitations
- Low stiffness — 35 GPa (5.08 Msi), worse than 100% of magnesium alloy grades
- Limited ductility — 1%, worse than 100% of magnesium alloy grades
- Low fracture toughness — 6 MPa·√m (5.46 ksi·√in), worse than 100% of magnesium alloy grades
- Poor heat conductor — 40 W/m·K (23.1 BTU/hr·ft·°F), worse than 100% of magnesium alloy grades
- Low electrical conductivity — 9 % IACS, worse than 100% of magnesium alloy grades
AZ91D Powder BJT-SINT properties
Typical room-temperature values for AZ91D Powder BJT-SINT; 22 are specific to this condition. Other listed values are AZ91D Powder reference data and may not represent this condition. Bars are the position among magnesium alloy grades.
Physical3
AZ91D Powder BJT-SINT has a density of 1.65 g/cm³ (0.0596 lb/in³), lighter than 99% of magnesium alloy grades. It melts at 470°C (878 °F).
Mechanical14
AZ91D Powder BJT-SINT has a yield strength of 90 MPa (13.1 ksi) and a tensile strength of 120 MPa (17.4 ksi) — weaker than 96% of magnesium alloy grades. Elongation at break is 1% and the elastic modulus is 35 GPa (5.08 Msi).
Thermal6
AZ91D Powder BJT-SINT is rated for continuous service to 120°C (248 °F). It conducts heat at 40 W/m·K (23.1 BTU/hr·ft·°F), worse than 100% of magnesium alloy grades. Thermal expansion is 26 µm/m·K (14.4 µin/in·°F).
Electrical3
AZ91D Powder BJT-SINT conducts electricity at 9 % IACS, worse than 100% of magnesium alloy grades.
Chemical & Environmental3
Corrosion resistance is poor (15/100), worse than 94% of magnesium alloy grades.
Sustainability4
Producing a kilogram of AZ91D Powder BJT-SINT 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 BJT-SINT's machinability is excellent (85/100, worse than 100% of magnesium alloy grades); weldability fair (35/100); formability not recommended (5/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with AZ91D Powder BJT-SINT
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.
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.
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 | — |
AZ91D Powder BJT-SINT — frequently asked
What is AZ91D Powder BJT-SINT used for?
AZ91D Powder BJT-SINT 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 BJT-SINT?
AZ91D Powder BJT-SINT has a typical yield strength of 90 MPa (13.1 ksi) and a tensile strength of 120 MPa (17.4 ksi) — weaker than 96% of magnesium alloy grades. Strength varies by condition: see the 6 listed tempers.
Is AZ91D Powder BJT-SINT easy to machine?
Yes — machinability is rated excellent (85/100, worse than 100% 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 BJT-SINT be welded?
With care — weldability is rated fair (35/100). 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 BJT-SINT?
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 BJT-SINT 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 BJT-SINT?
AZ91D Powder BJT-SINT 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.
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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.