CNC custom mechanical parts base on AZ91 magnesium alloy

Explore AZ91 magnesium alloy, known for its lightweight properties, excellent corrosion resistance, and high strength-to-weight ratio. Ideal for aerospace, automotive, and structural applications, AZ91 delivers superior performance in demanding environments. Enhance your designs with this versatile and reliable magnesium alloy.

AZ91 magnesium

Trusted by buyers and engineers to create custom mechanical parts base on AZ91 magnesium.

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AGD has been very satisfied with SOURCIX's support, prompt responses, and attention to detail. We’ve decided to move forward with more projects and make SOURCIX our main service for development and prototypes, with plans to expand to full production soon.

Alberto Guerra

CEO at AGD PRODUCTIONS, Inc.

Los Angeles, CA USA

Trusted by leading companies

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Manufacturing process Type Type of items Common materials Typical tolerances

CNC

Milling

Complex 3D shapes
Enclosures and housings
Custom brackets
Prototypes
Mold and tooling

Aluminium 6061 / 7075
Steel 1018 / 4140
SST 304 / 316
Brass / Copper
Plastics (POM, ABS, Nylon)

+/- 0.01 mm to +/- 0.05mm

Turning

Cylindrical components
Shafts
Sleeves and bushings
Fittings
Custom threaded parts

Steel 4140 / 1045
SST 316 / 303
Titanium
Plastics (PTFE, PEEK)

+/- 0.01 mm to +/- 0.05mm

Sheet metal

Enclosures and chassis
Brackets
Panels
Covers and guards
Structural frames

Aluminium 5052
Steel
SST 304 / 316
Copper
Polycarbonate

+/- 0.5 mm to +/- 1mm

An In-Depth Look at AZ91 Magnesium Alloy

Properties and Applications of AZ91 Magnesium

Exploring AZ91 Magnesium: Properties and Applications of Custom Mechanical Parts

AZ91 magnesium alloy stands out as one of the most commonly used magnesium alloys due to its remarkable combination of strength, lightweight properties, and corrosion resistance. Known for its exceptional performance in applications requiring low-density materials, AZ91 has become a preferred choice in industries such as automotive, aerospace, electronics, and biomedical engineering. This article delves into the properties of AZ91 magnesium and its diverse applications.


What is AZ91 Magnesium?

AZ91 is a magnesium alloy characterized by its composition and properties, making it ideal for structural and lightweight applications. The name AZ91 comes from its chemical composition, which includes:

  • Aluminum (Al): ~9%, providing strength and improving corrosion resistance.
  • Zinc (Zn): ~1%, enhancing mechanical properties and corrosion resistance.
  • Magnesium (Mg): Balance (~90%), serving as the primary base metal.

This alloy’s balance of elements creates a material with excellent strength-to-weight ratio, good corrosion resistance, and impressive castability.


Key Properties of AZ91 Magnesium

1. Low Density

  • Density: ~1.81 g/cm³, making it 75% lighter than steel and 33% lighter than aluminum.
  • Ideal for applications where weight reduction is critical.

2. High Strength-to-Weight Ratio

  • Tensile strength: ~150 MPa to 230 MPa.
  • Yield strength: ~100 MPa.

3. Corrosion Resistance

  • Aluminum and zinc content form a protective oxide layer, improving resistance to environmental degradation.

4. Thermal Conductivity

  • Conductivity: ~96 W/m·K, aiding in heat dissipation for electronic and automotive components.

5. Good Castability

  • Excellent fluidity and low melting point (~595°C) allow for complex shapes and thin-walled structures.

6. Damping Capacity

  • Superior vibration damping properties make it ideal for components requiring reduced noise and vibrations.

7. Biocompatibility

  • Biodegradable properties make AZ91 a suitable material for temporary biomedical implants and other medical applications.

Applications of AZ91 Magnesium

1. Automotive Industry

  • Engine Blocks and Housings: Lightweight yet strong, improving fuel efficiency.
  • Transmission Cases: Reduced weight for better vehicle performance.
  • Steering Wheels: Combines durability with weight reduction.
  • Chassis Components: Enhances overall vehicle dynamics and reduces unsprung weight.

2. Aerospace Industry

  • Aircraft Components: Lightweight parts such as brackets, seat frames, and housings reduce fuel consumption.
  • Ducting Systems: Excellent thermal properties for efficient heat management.
  • Satellite Structures: Provides low mass with the required structural rigidity for space applications.

3. Electronics

  • Laptop Casings: Combines lightweight and thermal conductivity.
  • Heat Sinks: Dissipates heat effectively in electronic devices.
  • Camera Frames: Durable and lightweight for handheld use.
  • Mobile Device Housings: Protects internal components while reducing overall weight.

4. Biomedical Engineering

  • Orthopedic Implants: Biocompatibility and biodegradability for temporary implants.
  • Surgical Tools: Lightweight and corrosion-resistant instruments.
  • Bone Screws and Plates: Degrades safely in the body after fulfilling its purpose, reducing the need for secondary surgeries.

5. Industrial Applications

  • Power Tool Housings: Durable and lightweight for ergonomic designs.
  • Robotics Components: High strength-to-weight ratio for mobile and structural parts.
  • Piping and Tubing: Used in chemical and industrial environments where weight reduction is needed.

Advantages of AZ91 Magnesium in Custom Parts

1. Weight Reduction

  • Reduces component weight significantly, improving efficiency in automotive and aerospace applications.

2. Improved Fuel Efficiency

  • Lightweight components reduce the energy required for transportation, enhancing fuel economy.

3. Enhanced Design Flexibility

  • Excellent castability and machinability allow for complex shapes and tight tolerances.

4. Corrosion Resistance

  • Protective oxide layers and surface treatments extend the lifespan of components.

5. Damping Properties

  • High damping capacity reduces noise and vibrations in structural and mechanical applications.

6. Sustainability

  • Magnesium is fully recyclable, contributing to environmentally friendly manufacturing practices.

Challenges in Using AZ91 Magnesium

1. Flammability

  • Magnesium is flammable at high temperatures; proper handling and manufacturing protocols are critical.

2. Corrosion in Harsh Environments

  • While AZ91 resists corrosion in many environments, prolonged exposure to chlorides or aggressive chemicals may degrade the material.

3. Limited Weldability

  • Welding requires precise control and specialized techniques to avoid cracking or weakening.

4. Material Cost

  • Raw magnesium can be more expensive than other common materials like aluminum or steel.

5. Brittle Behavior

  • AZ91 can exhibit brittleness under certain stress conditions, requiring careful design to avoid stress concentrations.

 

Manufacturing Techniques and Future Advancements for AZ91 Magnesium


Manufacturing Processes for AZ91 Magnesium Custom Parts

Custom parts made from AZ91 magnesium require specialized manufacturing techniques to achieve desired properties and dimensions. Below are the primary methods used:

1. Casting

  • Die Casting: The most common method for AZ91 magnesium, enabling high-volume production with excellent dimensional accuracy.
  • Sand Casting: Suitable for larger parts with complex geometries and lower production volumes.
  • Gravity Casting: Used for medium-sized components requiring precise structural integrity.
  • Permanent Mold Casting: Enhances mechanical properties through improved microstructural control.

2. CNC Machining

  • Ideal for producing intricate and precise custom parts.
  • Tooling Considerations:
    • Carbide tools with coatings are preferred to minimize wear.
    • Proper coolant systems are essential to avoid thermal damage.
  • Tolerances of ±0.01 mm are achievable, ensuring high precision.
  • Advanced multi-axis machines allow the creation of complex geometries in a single setup.

3. Extrusion

  • Produces long components such as tubes and rods with uniform cross-sections.
  • Improves mechanical properties through grain alignment.
  • Enhanced techniques enable the creation of thin-walled extrusions for lightweight structures.

4. Additive Manufacturing

  • Selective Laser Melting (SLM) and other 3D printing technologies are being explored for complex geometries and rapid prototyping.
  • Hybrid manufacturing processes combine additive and subtractive techniques to optimize material usage.

5. Surface Treatments

  • Anodizing: Enhances corrosion resistance and surface hardness.
  • Plating: Applies additional protective or decorative coatings.
  • Painting: Provides aesthetic appeal and environmental protection.
  • Micro-Arc Oxidation (MAO): Creates a ceramic-like layer on the surface for improved durability.

Advancements in AZ91 Magnesium Technology

1. Enhanced Corrosion Resistance

  • New alloying techniques and surface treatments are improving the corrosion resistance of AZ91 magnesium.

2. Improved Casting Technologies

  • Advanced die-casting methods enable thinner walls and more intricate geometries while reducing defects.

3. Hybrid Manufacturing

  • Combining casting with additive manufacturing for optimized designs and material efficiency.

4. AI-Driven Design

  • Artificial intelligence and machine learning tools optimize component designs for weight reduction and stress distribution.

5. Recycling Innovations

  • Improved recycling methods reduce the environmental impact and cost of AZ91 magnesium components.

Case Studies

1. Automotive Gear Housings

  • Challenge: Develop lightweight gear housings to improve vehicle performance.
  • Solution: AZ91 magnesium parts reduced weight by 35% compared to aluminum, enhancing fuel efficiency.

2. Aerospace Seat Frames

  • Challenge: Reduce weight without compromising strength.
  • Solution: AZ91 magnesium frames achieved a 40% weight reduction, allowing increased payload capacity.

3. Electronics Heat Sinks

  • Challenge: Create efficient heat sinks for high-power devices.
  • Solution: Custom AZ91 magnesium heat sinks improved thermal management by 20% while reducing weight.

4. Biomedical Screws

  • Challenge: Provide biocompatible and biodegradable temporary implants.
  • Solution: AZ91 magnesium screws dissolved safely in the body after healing, eliminating the need for removal surgery.

5. Robotics Components

  • Challenge: Create lightweight yet strong structural parts for robotic arms.
  • Solution: AZ91 magnesium components improved mobility and reduced power consumption by 15%.

Metrics for Evaluating AZ91 Magnesium Parts

  • Weight Savings: Achieve up to 50% weight reduction compared to steel components.
  • Thermal Efficiency: Enhanced heat dissipation in electronic applications.
  • Dimensional Accuracy: Achieving tolerances within ±0.01 mm.
  • Corrosion Resistance: Extended service life in moderate environments.
  • Sustainability: Fully recyclable material for eco-friendly manufacturing.

Conclusion

AZ91 magnesium offers an exceptional combination of lightweight properties, strength, and corrosion resistance, making it a preferred material for custom mechanical parts in various industries. While challenges such as flammability and weldability persist, advancements in manufacturing and design continue to unlock new possibilities for this versatile alloy. From automotive to biomedical engineering, AZ91 magnesium is shaping the future of lightweight, high-performance components, ensuring its relevance in modern and emerging applications.