Al 2024 powder
Al 2024 powder is an aluminum alloy that primarily consists of aluminum, copper, and small amounts of magnesium and manganese. This alloy exhibits exceptional strength and excellent fatigue resistance, making it ideal for applications where lightweight materials with high mechanical properties are required. Al 2024 powder is commonly used in industries such as aerospace, automotive, and sporting goods.
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Table of Contents
Overview of Al 2024 Powder
Al 2024 is one of the most popular 2000 series wrought aluminum alloys known for its strength, fatigue resistance, and excellent machinability and corrosion resistance. The copper additions impart substantial strengthening through precipitation hardening while retaining formability and weldability.
Key characteristics of Al 2024 powder include:
- High strength with moderate ductility and toughness
- Excellent fatigue and fracture resistance
- Very good machinability and polishability
- Good weldability and formability
- High thermal and electrical conductivity
- Available in range of powder sizes and shapes
Al 2024 powder is suitable for aerospace components and other high-performance applications needing strength combined with fabrication capabilities.
Chemical Composition of Al 2024 Powder
The typical composition of Al 2024 powder is:
| Element | Weight % |
|---|---|
| Aluminum (Al) | 90.7-94.7% |
| Copper (Cu) | 3.8-4.9% |
| Magnesium (Mg) | 1.2-1.8% |
| Manganese (Mn) | 0.3-0.9% |
| Iron (Fe) | 0-0.5% |
| Silicon (Si) | 0-0.5% |
| Zinc (Zn) | 0-0.25% |
| Chromium (Cr) | 0-0.1% |
| Titanium (Ti) | 0-0.15% |
Copper is the principal alloying element while magnesium imparts strength through precipitation hardening. Other elements like manganese, iron, and chromium have minor effects on mechanical properties.
Properties of Al 2024 Powder
Key properties of Al 2024 powder include:
| Property | Value |
|---|---|
| Density | 2.77 g/cm3 |
| Melting Point | 500-638°C |
| Thermal Conductivity | 121-190 W/mK |
| Electrical Conductivity | 26-35% IACS |
| Young’s Modulus | 73 GPa |
| Poisson’s Ratio | 0.33 |
| Tensile Strength | 400-500 MPa |
| Yield Strength | 290-385 MPa |
| Elongation | 8-20% |
| Hardness | 90-150 Vickers |
The copper additions result in substantial increase in strength while maintaining moderate ductility and excellent fatigue strength through precipitation hardening. It offers optimal combination of properties for high-performance applications.
Production Method for Al 2024 Powder
Commercial production methods for Al 2024 powder include:
- Gas Atomization – Molten alloy stream disintegrated by high pressure inert gas jets into fine spherical powder. Controlled particle size distribution.
- Water Atomization – High velocity water jet impacts and disintegrates molten metal stream to produce fine irregular powder.
- Mechanical Alloying – Ball milling a mixture of aluminum and alloying element powders followed by cold compaction and sintering.
- Electrolysis – Aluminum produced through electrolysis process and then alloyed and atomized.
Gas atomization provides the best control over particle characteristics like size, shape and microstructure.
Applications of Al 2024 Powder
Key applications of Al 2024 powder include:
- Additive Manufacturing – Used in selective laser melting, direct metal laser sintering to produce complex aerospace and automotive components.
- Metal Injection Molding – To manufacture small intricate parts with good mechanical properties and corrosion resistance.
- Powder Metallurgy – Press and sinter process to create high performance automotive and machinery parts.
- Thermal Spraying – Plasma or arc spraying to deposit protective Al 2024 coatings against wear and corrosion.
- Welding Filler – Used as filler wire/rod for arc welding of aluminum alloys. Provides excellent weld strength.
- Pyrotechnics – Added to pyrotechnic compositions as fuel due to flammability of aluminum.
Specifications of Al 2024 Powder
Al 2024 powder is available in different size ranges, shapes and grades including:
- Particle Size: From 10 – 150 microns for AM, up to 300 microns for thermal spray processes.
- Morphology: Spherical, granular, dendritic and irregular shaped particles. Smooth powder flows better.
- Grades: Conforming to AMS 4255, ASTM B221, EN 573-3, ISO 209 specifications and other custom grades.
- Purity: From commercial to high purity levels based on chemical composition and application needs.
Global Suppliers of Al 2024 Powder
Some of the major suppliers globally are:
- Sandvik Osprey (UK)
- Valimet Inc. (USA)
- TLS Technik (Germany)
- CNPC Powder Group (China)
- Metal Powder Company (USA)
- Makin Metal Powders (UK)
- AMETEK Reading Alloys (USA)
These companies produce Al 2024 powder suitable for AM, thermal spray, automotive, aerospace and other demanding applications.
Al 2024 Powder Pricing
Pricing of Al 2024 powder depends on factors like:
- Purity levels
- Powder characteristics and quality
- Production method
- Order quantity
- Supplier and location
| Grade | Price Range |
|---|---|
| Commercial | $8-15 per kg |
| High purity | $15-30 per kg |
| Ultrafine | $30-60 per kg |
| Special grade | $50-100 per kg |
Gas atomized, high purity and custom alloys command much higher pricing than simple commercial grades of powder.
Storage and Handling of Al 2024 Powder
Al 2024 powder requires careful storage and handling to prevent:
- Oxidation and reaction with moisture
- Dust explosions from ignition of fine powder
- Inhalation related health problems
- Safety practices recommended by supplier should be followed
Inert gas blanketing, proper grounding, ventilation, and PPE should be used when handling the powder.
Testing and Characterization Methods
Key test methods used for Al 2024 powder include:
- Chemical analysis using OES or XRF spectroscopy
- Particle size distribution as per ASTM B822 standard
- Morphology analysis through scanning electron microscopy
- Powder flow rate measurement using Hall flowmeter
- Density measurement by helium pycnometry
- Impurities testing by ICP-MS
- Microstructure examination by X-ray diffraction
These tests ensure the powder meets the required chemistry, physical characteristics, and microstructure as per application needs.
Comparison Between Al 2024 and Al 7075 Powder
Al 2024 and Al 7075 are two high strength aluminum alloy powders compared:
| Parameter | Al 2024 | Al 7075 |
|---|---|---|
| Alloy type | Heat treatable | Heat treatable |
| Cu content | 3.8-4.9% | 1.2-2% |
| Zn content | 0-0.25% | 5.1-6.1% |
| Strength | High | Very high |
| Fracture toughness | Higher | Moderate |
| Corrosion resistance | Good | Moderate |
| Weldability | Fair | Poor |
| Cost | Lower | Higher |
Al 2024 offers better fabricability whereas Al 7075 provides very high strength after heat treatment. Al 2024 is more cost effective.
Al 2024 Powder FAQs
Q: How is Al 2024 powder produced?
A: Al 2024 powder is commercially produced using gas atomization, water atomization, mechanical alloying, and electrolysis techniques. Gas atomization offers the best control of particle size and morphology.
Q: What are the main applications of Al 2024 powder?
A: The major applications include additive manufacturing, thermal spraying, powder metallurgy, metal injection molding, welding filler, and pyrotechnic compositions where high strength and good corrosion resistance is required.
Q: What is the typical particle size used for Al 2024 powder in AM?
A: In most metal 3D printing processes, the ideal particle size range for Al 2024 powder is 15-45 microns with spherical morphology and good flow characteristics.
Q: Does Al 2024 powder require any special handling precautions?
A: Yes, it is recommended to handle fine aluminum powders under inert gases using proper grounding, ventilation and PPE to prevent risk of fires and explosions.
Q: Where can I buy Al 2024 powder suitable for aerospace components?
A: High purity gas atomized Al 2024 powders meeting aerospace requirements can be sourced from companies like Sandvik Osprey, Valimet Inc., TLS Technik, and AMETEK Reading Alloys.
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