Al 3004 powder

Overview of Al 3004 Powder

Al 3004 is a wrought aluminum alloy known for its moderate strength, excellent corrosion resistance, good formability and weldability. Manganese enhances strength through solid solution strengthening while magnesium improves strength through precipitation hardening.

Key characteristics of Al 3004 powder include:

• Moderate tensile strength with excellent ductility
• Very good formability and weldability
• Excellent corrosion resistance
• High thermal and electrical conductivity
• Low density
• Available in various particle size distributions

Al 3004 powder is suitable for applications requiring moderate strength combined with good weldability, machinability and corrosion resistance.

Chemical Composition of Al 3004 Powder

The typical composition of Al 3004 powder is:

Element	Weight %
Aluminum (Al)	Balance
Manganese (Mn)	1.0-1.5%
Magnesium (Mg)	0.2-0.8%
Silicon (Si)	0-0.6%
Iron (Fe)	0-0.7%
Copper (Cu)	0-0.25%
Chromium (Cr)	0-0.10%
Zinc (Zn)	0-0.10%

Manganese and magnesium are intentionally added alloying elements while silicon, iron, copper, and zinc are present as impurities.

Properties of Al 3004 Powder

Key properties of Al 3004 powder include:

Property	Value
Density	2.73 g/cm3
Melting Point	630-655¡«C
Thermal Conductivity	180 W/mK
Electrical Conductivity	41-43 %IACS
Young’s Modulus	68-72 GPa
Poisson’s Ratio	0.33
Tensile Strength	190-240 MPa
Yield Strength	110-170 MPa
Elongation	10-20%
Hardness	50-65 Brinell

 

The alloy offers moderate strength with excellent ductility and formability. It has good resistance to atmospheric corrosion. Thermal and electrical conductivity is high.

Production Method for Al 3004 Powder

Common production methods for Al 3004 powder include:

• Gas Atomization?- Molten alloy stream disintegrated by inert gas jets into fine spherical powder with controlled particle distribution.
• Water Atomization?- High velocity water jet used to produce fine irregular Al 3004 particles. Lower cost but higher oxygen content.
• Mechanical Alloying?- Ball milling a blend of aluminum and alloying powders followed by cold compaction and sintering.

Gas atomization provides superior control over powder characteristics critical for advanced applications.

Applications of Al 3004 Powder

Typical applications of Al 3004 powder include:

• Additive Manufacturing?- Used in binder jetting, laser melting, electron beam melting processes to produce complex aluminum parts.
• Metal Injection Molding?- To manufacture small intricate components that need good strength and corrosion resistance.
• Powder Metallurgy?- Press and sinter process to produce moderately high-performance automotive and machinery parts.
• Thermal Spraying?- Wire arc spray deposition to produce protective coatings offering moderate wear and corrosion resistance.
• Welding Filler?- Used as filler wire to provide weld strength similar to base metal.
• Pigments?- Added to paints and coatings to provide shine and corrosion protection.

Specifications of Al 3004 Powder

Al 3004 powder is available under different size ranges, shapes, purity levels, and grades:

• Particle Size:?From 10-150 microns for AM methods, up to 300 microns for thermal spray processes.
• Morphology:?Spherical, granular, irregular and flake powder shapes are available.
• Purity:?From commercial grades up to high purity levels based on impurity limits.
• Grades:?Conforming to ASTM B209, EN 573, and ISO 209 specifications. Custom grades offered.
• Flowability:?Powder can be customized for specific flow rates as per application requirements.

Global Suppliers of Al 3004 Powder

Some of the major global suppliers are:

• Valimet Inc. (USA)
• Makin Metal Powders (UK)
• Atomization Systems Limited (Canada)
• SCM Metal Products (USA)
• Shanghai Chaowei Nanotechnology (China)
• Agni Metal (USA)
• Titanium Powder (Russia)

These companies produce Al 3004 powder suitable for AM, thermal spray, automotive, aerospace, and general engineering applications.

Al 3004 Powder Pricing

Pricing of Al 3004 powder depends on factors like:

• Purity levels
• Particle size distribution
• Powder morphology and shape
• Order quantity
• Supplier and geographical location

Grade	Price Range
Commercial	$5-15 per kg
High purity	$15-25 per kg
Ultrafine	$25-45 per kg
Special grade	$45-90 per kg

 

Spherical, controlled particle size and high purity grades are costlier than simple commercial Al 3004 powder.

Storage and Handling of Al 3004 Powder

Al 3004 powder should be properly handled and stored to prevent:

• Oxidation and reaction with moisture
• Dust explosion hazards from fine powder
• Inhalation related health problems
• Safety practices from supplier SDS should be followed

Inert gas blanketing, proper grounding, ventilation, and PPE is recommended when handling the powder.

Testing and Characterization Methods

Key test methods used for Al 3004 powder include:

• Chemical composition analysis using OES or XRF
• Particle size distribution as per ASTM B822 standard
• Morphology analysis through SEM
• Powder flow rate measured by Hall flowmeter
• Density determined by helium pycnometry
• Impurity level testing by ICP-MS
• Microstructure examination by X-ray diffraction

These tests ensure batch-to-batch consistency and that the powder meets application requirements.

Comparison Between Al 3004 and Al 6061 Powders

Al 3004 and Al 6061 are two aluminum alloy powders compared:

Parameter	Al 3004	Al 6061
Alloy type	Non-heat treatable	Heat treatable
Mg content	0.2-0.8%	0.8-1.2%
Strength	Moderate	Higher
Corrosion resistance	Excellent	Excellent
Weldability	Excellent	Good
Machinability	Good	Excellent
Cost	Lower	Higher

 

Al 3004 offers better weldability while Al 6061 has higher strength. Both offer excellent corrosion resistance.

Al 3004 Powder FAQs

Q: How is Al 3004 powder produced?

A: Al 3004 powder is commercially produced using gas atomization, water atomization, and mechanical alloying followed by sintering. Gas atomization provides the best control of particle characteristics.

Q: What are the main applications of Al 3004 powder?

A: The major applications of Al 3004 powder include additive manufacturing, thermal spray coatings, powder metallurgy parts manufacturing, metal injection molding, pigments, and welding filler wire.

Q: What is the recommended particle size for Al 3004 powder for binder jet 3D printing?

A: For binder jetting process, the typical Al 3004 powder size range is 20-45 microns with near-spherical morphology to provide good powder bed density and binder infiltration.

Q: Does Al 3004 powder require any special handling precautions?

A: Yes, it is recommended to handle aluminum powders carefully under inert atmosphere using proper grounding, ventilation and PPE to prevent fire or explosion hazards.

Q: Where can I buy Al 3004 powder suitable for aerospace welding wire?

A: High purity gas atomized Al 3004 powder meeting aerospace standards can be purchased from leading manufacturers like Valimet, Makin Metal Powders, and ASL.