1. 導入

AlSi10Mg Alloy represents a benchmark in the Al‑Si‑Mg family, combining exceptional castability with a high strength‑to‑weight ratio.

Widely adopted across aerospace, 自動車, およびエレクトロニクス産業, this alloy leverages its ~10 wt% silicon content to achieve fluidity and thin‑wall capability, while its magnesium addition enables precipitation hardening for enhanced mechanical performance.

In both traditional casting routes, such as high‑pressure die casting and gravity die casting,

and advanced additive manufacturing processes like Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLM), AlSi10Mg continues to set the standard for high‑performance, lightweight components.

2. What is AlSi10Mg Alloy?

AlSi10Mg is a hypoeutectic アルミニウム合金 belonging to the widely used Al‑Si casting family.

Its nominal chemical composition is approximately 89 wt% aluminum, 9–11 wt% silicon, and 0.2–0.5 wt% magnesium, with trace levels of iron, マンガン, and titanium to control intermetallic formation and refine grain structure.

Because of its balanced silicon and magnesium content, AlSi10Mg combines the fluidity and low melting range typical of Al‑Si alloys with the age‑hardening capability endowed by Mg₂Si precipitates.

This makes it exceptionally versatile across both conventional and powder‑based manufacturing techniques.

Classification and Equivalents

• EN AC‑43000 (あなたのもの 1706): European designation for sand, 死ぬ, and gravity castings.
• ASTM A360/A360M: North American standard covering permanent mold castings for general engineering.
• ISO 945‑2: Governs chemical composition tolerances for AlSi10Mg in wrought and cast forms.

3. Chemical Composition of AlSi10Mg Aluminum Casting Alloys

The performance of AlSi10Mg stems directly from its carefully balanced chemistry. Below is a summary of the typical composition ranges and the metallurgical roles each element plays.

4. Mechanical Properties of AlSi10Mg Aluminum Casting Alloys

AlSi10Mg exhibits a versatile mechanical profile that can be tailored through choice of casting process and heat‐treatment regimen.

In its as‑cast or as‑built state, the alloy delivers a balance of strength and ductility suitable for many applications.

5. Physical Properties of AlSi10Mg Alloys

AlSi10Mg combines the lightweight and thermal performance of aluminum with silicon‑enhanced stability, making it an excellent choice where thermal management and dimensional control are critical.

Its physical constants are largely invariant across casting and AM processes, though minor variations can arise from porosity levels and microstructural differences.

6. Castability and Processing Techniques of AlSi10Mg Alloy

AlSi10Mg’s castability is among the best in the aluminum alloy family, largely due to its silicon content (9.0–11.0 wt%) which reduces the melting range to 570–610 °C and increases molten metal fluidity.

This enables precise replication of complex geometries across various casting and additive manufacturing methods.

Key Castability Traits

• 流動性: The high silicon concentration reduces melt viscosity, enabling filling of intricate cavities with sharp transitions and thin walls.
  AlSi10Mg can achieve wall thicknesses as low as 0.5–1 mm in controlled conditions, outperforming A356 and similar alloys.
• Shrinkage Behavior: Displays predictable volumetric solidification shrinkage of 5–7%, manageable through proper gating/riser design and thermal control. Its eutectic Al–Si structure helps reduce hot tearing susceptibility.
• 気孔抵抗: In optimized casting and AM processes, gas and shrinkage porosity can be limited to <1–2％, preserving mechanical integrity.
  Controlled atmospheres or vacuum-assisted processing further reduce porosity risk.

Processing Techniques for AlSi10Mg

高圧ダイキャスティング (HPDC)

• プロセス:
  Molten AlSi10Mg is injected into hardened steel dies at high pressures typically ranging from 10 に 150 MPA using a plunger system.
  The injection is rapid (filling time <0.5 秒), enabling high production efficiency and dimensional repeatability.
  Mold temperatures are maintained between 180–250°C to control cooling rates and minimize thermal shock.
• 利点: Excellent for mass production (まで 100,000+ 毎年ユニット), with precise dimensional tolerances (±0.1 mm) そして、良い表面仕上げ (RA3.2-6.3μm).
• アプリケーション: 伝送ケース, モーターハウジング, and consumer electronics enclosures.
• 制限: High cooling rates and gas entrapment can cause porosity, limiting suitability for high-integrity or load-critical parts.

重力ダイキャスティング (GDC)

• プロセス:
  Molten AlSi10Mg is poured into a preheated permanent mold (通常 200–350°C) using gravity alone. Pouring is controlled to minimize turbulence and oxidation.
  The slower filling and natural flow promote fewer gas inclusions and better surface quality compared to HPDC.
• 利点: Yields better mechanical properties (2–5% higher strength) and is suitable for mid-volume runs (10,000–50,000 parts).
• アプリケーション: EV battery trays, structural engine mounts, ポンプコンポーネント.
• Strength Note: Slower cooling promotes slightly coarser microstructures but better ductility than HPDC.

低圧鋳造 (LPC)

• プロセス:
  AlSi10Mg is held in a sealed crucible furnace below the mold. A pressure of 0.5–1.5 MPa 適用されます, pushing molten metal upward through a riser tube into the mold.
  This bottom-up filling minimizes turbulence and enables precise temperature control.
• 利点: 密なものを生成します, defect-free parts (≥99% density) with excellent mechanical integrity and minimal turbulence.
• アプリケーション: 航空宇宙タービンコンポーネント, structural automotive parts, and fuel distribution manifolds.

砂鋳造

• プロセス:
  パターン (often 3D printed or CNC machined) are used to form sand molds (resin or clay-bonded). Molten AlSi10Mg is manually or automatically poured into the cavity at 680–730 °C.
  Cooling occurs naturally in ambient conditions, producing coarse microstructures unless modified.
• 利点: High design flexibility and low tooling costs ($500 - $ 5,000). Capable of producing components weighing up to 100 kg.
• Surface and Tolerances: Typical rougher finish (RA12.5-25μm); tolerances around ±0.5 mm.
• アプリケーション: Industrial pump housings, large structural elements, and pre-series automotive parts.

インベストメント鋳造 (紛失したワックスキャスティング)

• プロセス:
  A wax model is coated with ceramic slurry and stuccoed in multiple layers to form a shell. After dewaxing and firing (〜900°C), molten AlSi10Mg is poured into the shell.
  Castings are cooled, shell is removed, and parts are cleaned.
• 利点: Extremely fine detail (に 0.5 mm壁の厚さ), タイトな寸法制御 (±0.05 mm), そして優れた表面仕上げ (RA1.6-3.2μm).
• アプリケーション: Aerospace instrumentation components, 手術器具, and miniature gear systems.

添加剤の製造 (レーザーパウダーベッドフュージョン, LPBF / DMLS)

• プロセス:
  Fine AlSi10Mg powder (通常 20–60 μm) is spread in thin layers. A high-power fiber laser (200–500 W) selectively melts the powder layer by layer in a protective argon or nitrogen environment.
  The build plate is preheated (～100～200℃) to reduce residual stress.
• 利点: Unmatched geometric freedom, ideal for lattice structures, 内部冷却チャネル, トポロジー最適化されたデザイン. Post-build treatments such as stress relief (200–300°C) and HIP can boost fatigue life by up to 30%.
• アプリケーション: Lightweight aerospace brackets (例えば。, 40% 体重減少), motorsport suspension systems, UAV chassis, and custom orthopedic implants.

7. Heat Treatment of AlSi10Mg Alloy

Heat treatment is essential for optimizing the mechanical properties of AlSi10Mg aluminum casting alloys by refining its microstructure and enhancing strength, 延性, および寸法の安定性.

The alloy responds well to various tempering processes, each tailored to specific performance needs.

T6気性 (溶液処理 + 人工老化):

This is the most commonly applied heat treatment for AlSi10Mg, designed to maximize strength and fatigue resistance.

The process involves heating the alloy to approximately 505–540°C (溶液処理) to dissolve magnesium and silicon into a solid solution, followed by rapid quenching to retain this supersaturated state.

The final step is artificial aging at 160–180°C for 6–10 hours, promoting fine Mg₂Si precipitates that significantly increase tensile strength.

• 機械的特性: Tensile strength of 250–290 MPa, yield strength of 180–230 MPa, and elongation of 2–5%.
• アプリケーション: Ideal for high-stress, load-bearing components such as aerospace brackets, 自動車サスペンション部品, and engine housings where high strength and fatigue resistance are critical.

T4 テンパー (溶液処理 + 自然な老化):

T4 treatment also begins with solution annealing at similar temperatures but relies on natural aging at room temperature over several days.

This yields improved ductility compared to T6, at the expense of somewhat lower strength.

• 機械的特性: Tensile strength around 200–230 MPa, yield strength about 130–160 MPa, and elongation of 6–8%.
• アプリケーション: Suitable for parts requiring subsequent forming or machining after casting, such as housings and structural components needing higher toughness and flexibility.

T5 テンパー (Artificial Aging Only):

In T5, the alloy is artificially aged after casting or additive manufacturing without prior solution treatment, typically at 160–180°C for 6–8 hours.

• 機械的特性: Tensile strength between 230–260 MPa and elongation of 3–6%.
• アプリケーション: Used for thin-walled or dimensionally sensitive components where distortion must be minimized, common in electronics housings and additively manufactured parts.

F Temper (As-Cast or As-Built Condition):

This temper involves no heat treatment, representing the alloy’s as-cast or as-built microstructure.

• 機械的特性: Tensile strength ranging from 150–200 MPa and elongation of 1–4%.
• アプリケーション: Non-critical or decorative parts where cost efficiency and rapid production are priorities.

ストレス緩和 (Specific to Additive Manufacturing):

Additive manufacturing processes like Laser Powder Bed Fusion generate residual stresses due to rapid heating and cooling cycles.

A stress-relief treatment at 200–300°C for a few hours reduces these stresses, improving part stability without significantly altering strength.

8. AlSi10Mg in Additive Manufacturing (3D 印刷)

AlSi10Mg is the most widely used aluminum alloy in laser-based 3D印刷:

• プロセス: レーザーパウダーベッドフュージョン (LPBF) and Direct Metal Laser Sintering (DMLS) fuse 20–60 µm AlSi10Mg powder layers into complex shapes.
• 利点:

• • Design freedom for lightweight lattices, 内部チャネル, and topology-optimized parts (例えば。, aerospace brackets with 40% 体重減少).
  • Near-net-shape production, reducing material waste to <5% (vs. 50–70% for machining).

• 後処理:

• • ストレス緩和: 200–300°C for 2–4 hours to reduce residual stress.
  • ヒップ (ホットアイソスタティックプレス): 100–200 MPa at 500–550°C eliminates porosity, improving fatigue strength by 20–30%.
  • 機械加工: Finishes critical surfaces (例えば。, 交尾インターフェイス) to ±0.01 mm.

キーアプリケーション: Motorsport suspension parts, drone frames, and medical prosthetics customized to patient anatomy.

9. 腐食抵抗と表面処理

AlSi10Mg’s natural corrosion resistance is moderate but enhanceable:

• Passive Layer: Forms a thin aluminum oxide (al₂o₃) 層, protecting against mild environments (例えば。, indoor air, 淡水).
• 表面処理:

• • 陽極酸化処理: Creates a porous oxide layer (10–50 µm thick) for improved wear/corrosion resistance; タイプIII (ハード陽極酸化) achieves 500+ HV hardness.
  • 粉体塗装: Adds a 50–150 µm polymer layer, ideal for outdoor applications (例えば。, 自動車トリム).
  • Chemical Conversion Coating: Chromate or zirconium treatments improve paint adhesion and corrosion resistance in humid environments.

• 制限: Susceptible to pitting in marine/chloride-rich environments (腐食率: 0.1–0.3 mm/year) without treatment.

10. Applications of AlSi10Mg Alloy

AlSi10Mg’s unique blend of castability, 強さ, and lightweight properties has made it a staple in diverse industries, where its ability to balance performance and manufacturability drives innovation.

航空宇宙と防御

AlSi10Mg is a workhorse in aerospace, where weight reduction and structural integrity are critical.

Its compatibility with both traditional casting and additive manufacturing (午前) enables complex, 高性能部品:

• 構造括弧: レーザーパウダーベッドフュージョン (LPBF)-printed brackets for aircraft and drones,
  featuring topology-optimized designs that reduce weight by 30–40% compared to machined alternatives while maintaining 280–320 MPa tensile strength (T6気性).
• エンジンハウジング: Gravity die-cast casings for auxiliary power units (APUs), leveraging the alloy’s heat resistance (up to 150°C) and corrosion resistance in high-humidity environments.
• UAV Components: Low-pressure cast rotor arms and payload bays, where AlSi10Mg’s 2.65 g/cm³ density enhances flight endurance.

自動車と輸送

The 自動車 industry relies on AlSi10Mg for its high-volume manufacturability and ability to reduce vehicle weight—key for improving fuel efficiency and electric vehicle (EV) 範囲:

• Engine Blocks and Transmission Cases: High-pressure die-cast (HPDC) コンポーネント, where the alloy’s fluidity enables thin walls (2–3 mm) and integrated cooling channels.
  T6 heat treatment provides 280 MPa tensile strength to withstand engine vibrations.
• EV Battery Enclosures: Large sand-cast or die-cast enclosures that protect battery packs from impact and corrosion.
  AlSi10Mg’s thermal conductivity (160–180W/m・K) aids in heat dissipation, preventing thermal runaway.
• サスペンションパーツ: Investment-cast control arms and knuckles, combining the alloy’s 200–230 MPa yield strength (T6) with fatigue resistance (110–130 MPa at 10⁷ cycles) to handle road stresses.

Major automakers report a 15–20% weight reduction in powertrain components when switching from cast iron to AlSi10Mg.

Electronics and Thermal Management

AlSi10Mg’s thermal conductivity and machinability make it ideal for エレクトロニクス, where heat dissipation and compact design are priorities:

• Heat Sinks and Cooling Plates: Die-cast or machined parts for servers, LED arrays, and EV chargers,
  using the alloy’s 160–180 W/m·K thermal conductivity to transfer heat away from sensitive components.
• Device Housings: LPBF-printed enclosures for rugged electronics (例えば。, industrial sensors), featuring integrated ribs and ports that eliminate assembly steps.
  The alloy’s corrosion resistance ensures durability in outdoor environments.
• 5G Antenna Brackets: 軽量, high-precision cast parts that maintain dimensional stability across temperature fluctuations (thanks to controlled thermal expansion).

医療およびヘルスケア

医療アプリケーションで, AlSi10Mg’s biocompatibility (when properly finished) and AM adaptability enable patient-specific solutions:

• Prosthetics and Orthopedics: 3D-printed prosthetic sockets and orthopedic braces, customized to CT scan data.
  The alloy’s low density (2.65 g/cm³) reduces user fatigue, while porous surface structures (achieved via LPBF) promote tissue integration.
• Surgical Instrument Housings: Investment-cast handles and casings, finished with electropolishing to meet FDA hygiene standards (21 CFR 177.1520).
  The alloy’s 70–80% machinability rating allows precise fitting of internal components.
• 診断機器: Die-cast frames for MRI and X-ray machines, where non-magnetic properties (no ferromagnetic elements) and vibration damping enhance imaging accuracy.

Industrial and Tooling

AlSi10Mg’s versatility extends to industrial machinery, where its cost-effectiveness and durability in moderate environments shine:

• ポンプおよびバルブコンポーネント: Sand-cast impellers and housings for water treatment and chemical processing, leveraging the alloy’s corrosion resistance in freshwater and mild chemicals.
  T6 temper ensures 280 MPa strength to withstand pressure up to 10 バー.
• 射出型: LPBF-printed mold inserts with conformal cooling channels, reducing cycle times by 20–30% compared to steel molds.
  AlSi10Mg’s thermal conductivity ensures uniform cooling of plastic parts.
• Conveyor Systems: Die-cast rollers and brackets, where the alloy’s wear resistance (enhanced via hard anodizing) and low maintenance needs reduce downtime in manufacturing facilities.

消費財と電子機器

In consumer products, AlSi10Mg balances aesthetics, 機能, コスト:

• Power Tool Housings: High-pressure die-cast casings for drills and saws, featuring impact-resistant designs (2–5% elongation in T6 temper) and a smooth surface finish (RA3.2-6.3μm) suitable for painting or branding.
• Laptop and Smartphone Frames: 3D-printed or die-cast chassis, where thin walls (1–2 mm) and lightweight construction improve portability.
  The alloy’s EMI shielding properties protect internal electronics.
• Sporting Equipment: Investment-cast components for bicycles (cranks, handlebars) and golf clubs, where strength-to-weight ratio (105–120 MPa/g/cm³ in T6 temper) enhances performance.

11. Advantages of AlSi10Mg Casting Alloys

• Exceptional Castability: Flows into thin walls (≥1mm) and complex molds, reducing machining needs by 30–50%.
• 熱の治療可能性: T6 temper achieves 280–320 MPa tensile strength—sufficient for most structural applications.
• 軽量: 2.65 g/cm³ density cuts fuel consumption in vehicles and improves payload capacity in aerospace.
• Additive Manufacturing Compatibility: LPBF/DMLS enables geometries impossible with traditional casting (例えば。, 中空, 格子構造).
• 費用対効果: Lower raw material costs than high-strength alloys (例えば。, 7075) and reduced processing expenses vs. アルミニウム.

12. Limitations and Challenges of AlSi10Mg Casting Alloy

• High-Temperature Weakness: Loses 30–40% strength above 150°C (例えば。, 200 MPa at 200°C vs. 280 MPa at 25°C), limiting use in engine hot zones.
• 耐摩耗性: Lower than cast iron or Al-Si alloys with higher silicon (例えば。, ALSI12), requiring hard anodizing for high-wear parts.
• Brittleness Risk: オーバーエイジング (T7 temper) or excessive iron content (>0.6%) reduces elongation to <1%, increasing fracture risk.
• 熱膨張の不一致: CTE (21–24 µm/m·K) is 2× higher than steel, causing stress in mixed-material assemblies (例えば。, bolted steel inserts).
• AM-Specific Issues: LPBF parts may exhibit anisotropic strength (10–15% lower in build direction) without post-heat treatment.

13. 他のアルミニウム合金との比較

14. 結論

AlSi10Mg stands as a versatile, high‑performance alloy that bridges traditional casting and cutting‑edge additive manufacturing.

Its combination of castability, 機械的堅牢性, and thermal properties suits a vast range of applications—from mass‑produced automotive parts to bespoke aerospace components.

While it faces limitations in high‑temperature and wear‑intensive environments, appropriate heat treatments and surface coatings extend its utility even further.

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FAQ

Can AlSi10Mg be used for structural aerospace parts?

はい. T6-tempered AlSi10Mg (280–320 MPa tensile) meets aerospace standards for non-critical structural parts (例えば。, ブラケット, ハウジング).

For high-load components, it is often paired with reinforcing ribs or 3D-printed lattice structures.

What’s the difference between AlSi10Mg and AlSi12?

AlSi12 has higher silicon (11–13％), improving fluidity for thinner walls (0.5 mm) but reducing strength (250 MPa T6 vs. 280 MPa for AlSi10Mg).

AlSi10Mg offers better machinability and ductility, making it more versatile.

Is AlSi10Mg good for machining?

はい. Its machinability rating (70–80％) is higher than many aluminum alloys, allowing fast turning, ミリング, and drilling with minimal tool wear—critical for finishing tight-tolerance parts (例えば。, バルブシート).

Does AlSi10Mg corrode?

It has moderate natural corrosion resistance in dry/freshwater environments but corrodes in marine/chloride-rich settings (0.1–0.3 mm/year).

Anodizing or powder coating extends service life in harsh conditions.

Is AlSi10Mg suitable for 3D printing?

Yes—it is the most common aluminum alloy in LPBF/DMLS. Its low melting range and good weldability enable strong layer fusion, 生産 99.9% dense parts with T6-equivalent strength.

Can AlSi10Mg be welded?

はい, しかし、注意して. It welds well using TIG or MIG methods with 4043 フィラー, though heat input may reduce strength in the heat-affected zone.