Modified Aluminum Alloys for High-Strain Applications

THE CHALLENGE

The key challenge in advancing high-strength aluminum alloys like the 7xxx and 6xxx series lies in bridging the gap between their exceptional mechanical potential and the limitations of current manufacturing methods. While industries such as aerospace and automotive demand lightweight materials with high strength and durability, existing processing techniques—like friction stir welding, extrusion, and additive friction stir deposition—introduce thermal and mechanical stresses that damage the alloys’ finely tuned microstructures. This leads to issues like cracking, porosity, and permanent loss of strength and ductility, which cannot be fully recovered even after heat treatments. As a result, manufacturers struggle to produce components that consistently meet performance and reliability standards. Overcoming this challenge requires innovation that maintains nanoscale precipitate stability during processing, enabling scalable production of next-generation lightweight materials with uncompromised structural integrity—crucial for industries where safety, performance, and efficiency are non-negotiable.

OUR SOLUTION

We offer a breakthrough manufacturing method for high-strength aluminum components by using a specially tailored alloy and a two-step processing route that overcomes the limitations of traditional techniques. By removing certain minor elements—like chromium, zirconium, and manganese—that typically cause embrittlement during severe plastic deformation (SPD), we enable the alloy to undergo high-speed processes such as friction stir welding or extrusion without compromising its strength or ductility. After a carefully controlled heat treatment, the alloy regains its full peak-aged properties, making it ideal for demanding applications in aerospace, automotive, and structural industries. This innovation not only improves material performance but also enhances manufacturing efficiency and scalability, unlocking new commercial opportunities for lightweight, high-performance components.

Figure: (a) Precipitation on a dispersoid particle in a grain interior (b) at a grain boundary

Advantages:

• Restores peak-aged strength and ductility after high-strain-rate processing
• Enables full-strength FSW, FSE, and AFSD using existing equipment
• Reduces alloying and manufacturing costs by up to 10%
• Improves fatigue performance and strength-to-weight ratio for lightweight components

Potential Application:

• Aerospace fuselage, wing, and landing gear components
• Automotive wheels, suspension parts, and engine blocks
• Defense and transportation vehicle structures
• Additive manufacturing and repair of high-strength aluminum parts