Metals for industrial 3D printing

3D printing aluminium

AlSi10Mg

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3D printing aluminium: the heavy-duty lightweight

Aluminium materials are often used in additive manufacturing processes. They are particularly suitable for applications and components requiring good mechanical properties, high stability and a light weight. 3D printing aluminium has high thermal conductivity and is extremely corrosion-resistant.

Which 3D printing aluminium is optimal?
After extensive testing of various alloys, we decided to use 3D printing aluminium AlSi10Mg for our production activities AlSi10Mg is proven in additive manufacturing and is one of the most common and versatile 3D printing aluminium materials currently available.

The impressive material properties of AlSi10Mg
3D printing aluminium AlSi10Mg consists of 89.5 % aluminium, 10 % silicon and 0.5 % magnesium. The combination of silicon and magnesium gives the aluminium alloy its special strength and hardness compared to other aluminium materials in additive manufacturing. This makes AlSi10Mg ideal for components that are exposed to high mechanical or dynamic loads.

Advantages of 3D printing aluminium AlSi10Mg
High dynamic load capacity
High strength
Very good hardness
Low weight
High thermal conductivity
High corrosion resistance
Airtight and waterproof

Fields of application of AlSi10Mg

3D printing aluminium AlSi10Mg is ideal for lightweight construction applications and components with thin-walled and complex geometries that are exposed to high stress. As a result, 3D printing aluminium is ideal for mechanical components in the aerospace, aviation, vehicle construction and bicycle industries, among others. 3D-printed components made of AlSi10Mg replace existing castings easily and equivalently. 3D printing aluminium AlSi10Mg enables the production of serial components in both large series and smaller batches, as well as the rapid production of technical prototypes (rapid prototyping).

Lightweight wheel carrier

A variety of geometrical solutions exist to accommodate the wheel bearing of a car and to replace the brake disc, brake caliper and, if necessary, the brakes. connect the drive shaft to the wheel carrier. Since the wheel carrier is only sprung or damped over the tire, it should be as light as possible. Lightweight construction in combination with aluminium as a material meets the requirements for weight savings with high strength and rigidity, as well as corrosion resistance.

Rapid prototyping |
Aluminium AlSi10Mg |
Radiate |
Checking the box dimensions |

Lightweight brake caliper

The brake caliper is part of the disc brake system. Its task is essentially to convert the hydraulic pressure in the braking system into a mechanical force. In cooperation with our engineering partner amprove, the component was further developed as a lightweight component by means of mathematical optimization. Lightweight construction in combination with aluminium as a material meets the requirements for weight savings with high strength and rigidity, as well as corrosion resistance. With the lightweight solution, a mass reduction of -20% (663 g), a stress reduction of -22% (-60 MPa), and an increase in stiffness of +26% (-0.37 ml at 150 bar) could be achieved.

Rapid prototyping |
Aluminium AlSi10Mg |
Radiate |
Checking the box dimensions |

3D Printing Cylinder Head

Cylinder heads are conventionally manufactured from aluminium using a low-pressure gravity die casting process. Thanks to additive manufacturing technologies, immediate tool- and mold-free manufacturing can significantly accelerate throughput times.

Rapid prototyping |
Aluminium AlSi10Mg |
Radiate |
Checking the box dimensions |

Co-engineering of a battery carrier for multi-variant, ultra-light small series

In the joint "VariKa" project of the Fraunhofer Institute for Lightweight Vehicles (LBF), FKM, together with engineering partners, has taken over the AM production of the bionic structural nodes made of high-strength aluminum. Additively manufactured fasteners are combined with standard extruded profiles to form a vehicle-specific lightweight battery carrier with an integrated joining function. To predict thermally induced deformations, simulations were carried out and the data set was geometrically optimized.

› Video

Rapid prototyping with functional integration |
Aluminium AlSi10Mg |
Sand blasting |
Examination of the box dimensions, subsequent analysis of structural characteristics of the material behavior, as well as experimental results |

AlSi10Mg

An extra-strong and hard 3D printing aluminium alloy

The combination of aluminium with 10 % silicon and 0.5 % magnesium gives the alloy special strength and hardness compared to other aluminium alloys. To further improve mechanical properties such as ductility and electrical and thermal conductivity, parts made of AlSi10Mg can also be heat-treated. The printing layers in the 3D printing process are between 0.03 and 0.1 millimetres thick with this 3D printing aluminium material. To ensure optimum break resistance and stability, the walls of the components should be at least 0.5 millimetres thick.

Maximum installation space: 800 x 400 x 500 mm

Properties of 3D printing aluminium AlSi10Mg

Mechanical

Yield strength Re 170 – 220 N/mm²
Tensile strength Rm 310 – 325 N/mm²
Elongation at break A 2 – 3 %
Modulus of elasticity ca. 75 • 10³ N/mm²

Thermal

Formbeständigkeitstemperatur (xy) 660,4°C
Thermal conductivity ʎ 120 – 180 W/mK
Coefficient of thermal expansion (at RT) 20 • 10-6K-1

Standards

DIN EN 1706

3D printing aluminium

AlSi10Mg

3D printing aluminium: the heavy-duty lightweight

AlSi10Mg

An extra-strong and hard 3D printing aluminium alloy

Properties of 3D printing aluminium AlSi10Mg

Mechanical

Thermal

Standards

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