Magnesium Alloy AZ91D Powder-HIP (Hot isostatic pressed)
Print state
Pick for fatigue- or pressure-critical printed parts where internal gas porosity and lack-of-fusion defects must be closed.
Values for the HIP 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 |
|---|---|---|---|---|---|---|
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 |
HIPThis page 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-HIP?
AZ91D Powder-HIP is AZ91D Powder in the HIP condition — pick for fatigue- or pressure-critical printed parts where internal gas porosity and lack-of-fusion defects must be closed. AZ91D Powder-HIP has a yield strength of 150 MPa (21.8 ksi) and a tensile strength of 280 MPa (40.6 ksi) — stronger than 59% of magnesium alloy grades. Elongation at break is 7% and the elastic modulus is 45 GPa (6.53 Msi). AZ91D Powder-HIP 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). AB is the default condition FabDigit quotes; HIP is available on request or by drawing note.
Limitations
- Poor heat conductor — 55 W/m·K (31.8 BTU/hr·ft·°F), worse than 90% of magnesium alloy grades
- Limited service temperature — 120°C (248 °F), worse than 78% of magnesium alloy grades
AZ91D Powder-HIP properties
Typical room-temperature values for AZ91D Powder-HIP; 21 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-HIP 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-HIP has a yield strength of 150 MPa (21.8 ksi) and a tensile strength of 280 MPa (40.6 ksi) — stronger than 59% of magnesium alloy grades. Elongation at break is 7% and the elastic modulus is 45 GPa (6.53 Msi).
Thermal6
AZ91D Powder-HIP is rated for continuous service to 120°C (248 °F). It conducts heat at 55 W/m·K (31.8 BTU/hr·ft·°F), worse than 90% of magnesium alloy grades. Thermal expansion is 26 µm/m·K (14.4 µin/in·°F).
Electrical3
AZ91D Powder-HIP conducts electricity at 13 % IACS, worse than 68% of magnesium alloy grades.
Chemical & Environmental3
Corrosion resistance is poor (26/100), better than 74% of magnesium alloy grades.
Sustainability4
Producing a kilogram of AZ91D Powder-HIP 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-HIP's machinability is excellent (95/100, better than 54% of magnesium alloy grades); weldability good (62/100); formability poor (22/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with AZ91D Powder-HIP
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-HIP — frequently asked
What is AZ91D Powder-HIP used for?
AZ91D Powder-HIP 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-HIP?
AZ91D Powder-HIP has a typical yield strength of 150 MPa (21.8 ksi) and a tensile strength of 280 MPa (40.6 ksi) — stronger than 59% of magnesium alloy grades. Strength varies by condition: see the 6 listed tempers.
Is AZ91D Powder-HIP 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-HIP be welded?
Yes — weldability is rated good (62/100). 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-HIP?
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-HIP 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-HIP?
AZ91D Powder-HIP 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.