OAK RIDGE, Tenn. — Researchers at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have successfully tested a new aluminum alloy, DuAlumin-3D, specifically engineered for additive manufacturing. The material demonstrates exceptional potential for producing high-temperature automotive components, overcoming a significant barrier in the 3D printing of lightweight metals.

The study highlights that DuAlumin-3D exhibits superior printability compared to conventional aluminum alloys, which are often prone to cracking during the laser powder bed fusion (LPBF) process. Crucially, it maintains thermal properties on par with existing materials, making it a viable candidate for applications where heat resistance and weight reduction are critical.

“DuAlumin-3D performed well in our evaluations, showing excellent resistance to hot cracking,” said ORNL lead researcher Alex Plotkowski. “While our initial focus is on high-efficiency engines, this alloy could readily be applied in aerospace or to innovate heat exchanger designs.”

Why It Matters: The development of an aluminum alloy that is both easy to 3D print and resistant to high temperatures could accelerate the adoption of additive manufacturing for critical components in cars and aircraft. This translates into more efficient engines, improved fuel economy, and greater design flexibility for industries where every gram and every degree Celsius counts.

A Global Push for Advanced Aluminum AM

This breakthrough at ORNL is part of a broader, international effort to advance aluminum additive manufacturing technologies:

• U.S. Defense Initiative: In May, Japan’s Nikon Corporation entered a $2.1 million agreement with the National Center for Defense Manufacturing and Machining (NCDMM) to advance metal AM for defense and aerospace. The program, funded by the Office of the Under Secretary of Defense, focuses on qualifying Constellium’s Aheadd CP1 aluminum alloy and involves industry partners including Lockheed Martin, Northrop Grumman, and RTX.
• Australian-US Navy Collaboration: Australian manufacturer AML3D extended a $370,000 AUD contract with BlueForge Alliance to test its Nickel-Aluminium-Bronze (NAB) alloys for the US Navy’s submarine program. As part of its US expansion strategy, AML3D has also installed a large-scale ARCEMY 3D printing system at Oak Ridge National Laboratory.
• UK R&D Partnership: Aluminium Materials Technologies (AMT) is collaborating with the University of Birmingham to deepen the metallurgical understanding of its A20X aluminum alloy when processed via LPBF and DED. The high-strength A20X is already widely used in aerospace and motorsports.

These concurrent developments underscore a global race to qualify and deploy next-generation aluminum alloys that can unlock the full potential of 3D printing for high-performance applications.

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