Elektron W4 Magnesium Alloy ，AZ92,E FOUR

### **Elektron W4 / AZ92 Magnesium Alloy** **Product Overview** Elektron W4, commercially designated as AZ92, is a high-strength magnesium-aluminum-zinc casting alloy that represents an enhanced version of the popular AZ91 alloy. With higher aluminum content, AZ92 delivers superior strength and hardness while maintaining good castability and moderate corrosion resistance. This alloy is particularly suited for applications requiring high mechanical strength and wear resistance in as-cast conditions, making it a preferred choice for structural components in automotive, aerospace, and industrial equipment. The alloy is commonly supplied as sand castings, permanent mold castings, and occasionally as die castings for applications where maximum strength is prioritized over ductility. --- #### **1. Chemical Composition** AZ92 features an elevated aluminum content compared to AZ91, contributing to its enhanced strength characteristics. | Element | Composition (% by Weight) | | :---------------- | :-------------------------------- | | **Aluminum (Al)** | 8.5 - 9.5 % | | **Zinc (Zn)** | 1.6 - 2.4 % | | **Manganese (Mn)** | 0.10 - 0.30 % | | **Silicon (Si)** | ≤ 0.20 % | | **Copper (Cu)** | ≤ 0.05 % | | **Iron (Fe)** | ≤ 0.005 % | | **Nickel (Ni)** | ≤ 0.002 % | | **Other Impurities** | ≤ 0.02 % (each) | | **Magnesium (Mg)** | Balance | *Note:* The higher **aluminum** content (compared to AZ91) increases the volume fraction of the hard Mg₁₇Al₁₂ intermetallic phase, resulting in improved strength and hardness. The elevated **zinc** content further enhances strength through solid solution strengthening, while **manganese** controls iron impurities to maintain adequate corrosion resistance. --- #### **2. Physical & Mechanical Properties** AZ92 exhibits the highest strength and hardness among standard Mg-Al-Zn casting alloys. **Physical Properties:** * **Density:** 1.82 g/cm³ (0.066 lb/in³) * **Melting Range:** 470 - 595 °C (878 - 1103 °F) * **Coefficient of Thermal Expansion:** 26.0 μm/m·°C (20-200°C) * **Thermal Conductivity:** 54 W/m·K * **Specific Heat Capacity:** 1050 J/kg·K **Typical Mechanical Properties (As-Cast):** * **Ultimate Tensile Strength (UTS):** 230 - 280 MPa (33 - 41 ksi) * **Tensile Yield Strength (TYS):** 150 - 180 MPa (22 - 26 ksi) * **Elongation:** 1 - 3% * **Compressive Yield Strength:** 150 - 180 MPa (22 - 26 ksi) * **Shear Strength:** 140 - 160 MPa (20 - 23 ksi) * **Hardness:** 75 - 85 HBW * **Modulus of Elasticity:** 45 GPa (6.5 × 10³ ksi) **Elevated Temperature Performance:** * **Maintains strength up to approximately 120°C (248°F)** * **Good wear resistance at room temperature** * **Limited creep resistance above 120°C** --- #### **3. International Standards & Specifications** AZ92 is recognized by several international standards organizations. * **ASTM International:** **ASTM B80** (Standard Specification for Magnesium-Alloy Sand Castings) * **ASTM International:** **ASTM B93** (Standard Specification for Magnesium-Alloy Die Castings) * **SAE International:** **SAE J465** * **UNS Designation:** **UNS M11920** * **German Standards:** **DIN MgAl9Zn2** * **ISO Standards:** **ISO 16220** * **Proprietary Designation:** **Elektron W4 / AZ92** (Luxfer MEL Technologies) --- #### **4. Product Applications** AZ92 is primarily used in applications requiring high strength and hardness. * **Automotive Industry:** * **Transmission Housings and Cases** * **Engine Bracket and Mounting Systems** * **High-Stress Structural Components** * **Differential Housings** * **Aerospace & Defense:** * **Gearbox Housings** * **Engine Accessory Housings** * **Missile Components** * **Aircraft Structural Brackets** * **Industrial Equipment:** * **Power Tool Housings** * **Compressor Housings** * **Pump Casings** * **High-Stress Machinery Components** * **Special Applications:** * **Racing Components** * **High-Performance Equipment Parts** * **Wear-Resistant Components** --- #### **5. Manufacturing Characteristics** **Casting Performance:** * Good castability with adequate fluidity * Higher tendency for microporosity compared to AZ91 * Suitable for both sand and permanent mold casting * Requires proper gating and risering design * Good pressure tightness in properly designed castings **Secondary Processing:** * Good machinability, though harder than AZ91 * Produces good surface finish * Responsive to heat treatment (T4, T5, T6) * Good response to surface treatments and coatings * Weldable with proper procedures --- **Summary** **Elektron W4 / AZ92 Magnesium Alloy** represents the high-strength variant in the Mg-Al-Zn alloy system, offering superior **mechanical strength** and **hardness** compared to the more common AZ91 alloy. The elevated **aluminum and zinc content** provides enhanced strength characteristics through increased volume of strengthening phases, making it suitable for applications where mechanical loading is the primary design consideration. While the alloy exhibits reduced ductility compared to AZ91, its compliance with international standards including **ASTM B80** and **ASTM B93** ensures reliable performance in structural applications. AZ92 continues to serve important roles in automotive, aerospace, and industrial sectors where its high strength-to-weight ratio and good wear resistance provide significant advantages over other materials, particularly in applications where maximum strength is required within the constraints of weight limitations.

Packing of Standard Packing: Typical bulk packaging includes palletized plastic 5 gallon/25 kg. pails, fiber and steel drums to 1 ton super sacks in full container (FCL) or truck load (T/L) quantities. Research and sample quantities and hygroscopic, oxidizing or other air sensitive materials may be packaged under argon or vacuum. Solutions are packaged in polypropylene, plastic or glass jars up to palletized 3410 gallon liquid totes Special package is available on request.