Multipurpose Ultra-strong Heat Resistant Aluminum Alloys for Additive Manufacturing

Multipurpose Ultra-strong Heat Resistant Aluminum Alloys for Additive Manufacturing

NU 2025-019

INVENTORS

• David Seidman*
• Amir Rezaei Farkoosh

SHORT DESCRIPTION
This technology comprises a series of ultra-high-strength, precipitation-hardened aluminum alloys specifically designed for laser additive manufacturing. The alloys deliver exceptional mechanical performance at both ambient and elevated temperatures while maintaining cost-effective production through broad processing windows and simplified post-processing.

BACKGROUND
Additive manufacturing has revolutionized component fabrication, yet the market lacks high-performance aluminum alloys capable of withstanding demanding ambient and high-temperature applications. Traditional alloys often fail to meet performance benchmarks due to thermal cycle challenges during processing, resulting in defects and anisotropic properties. This invention bridges that gap by providing heat-resistant, high-strength aluminum alloys optimized for AM, thereby enhancing design flexibility for industrial, defense, and transportation sectors.

ABSTRACT
The disclosed invention introduces a novel series of aluminum alloys, termed the NUAdd and NUAdd+ Alloy Series, which are optimized specifically for laser additive manufacturing processes such as selective laser melting (SLM) and directed energy deposition (DED). By employing an integrated computational materials engineering approach alongside extensive experimental validations, the alloys achieve ultra-high strength, excellent ductility, and outstanding creep resistance at elevated temperatures up to 400 °C. The alloys leverage multiple strengthening mechanisms including solute-induced threshold stresses, globular interdendritic nano-precipitates, and intra-dendritic age-hardening phases to establish a hierarchical microstructure that promotes isotropic mechanical properties without the need for extensive post-processing.

The technology’s innovation lies in its ability to produce near-theoretical densities with a random crystallographic texture, ensuring uniform behavior regardless of load direction. This print-and-go solution not only minimizes additional treatments like stress relief or hot isostatic pressing, but it also opens avenues for blending with conventional powders to further enhance performance. The process scalability has been validated in collaboration with industrial partners, ensuring the potential for large-scale commercialization across multiple sectors.

APPLICATIONS

• Internal combustion engine components: Suitable for engine blocks, cylinder heads, and pistons where high strength and heat resistance are critical.
• Electric vehicle components: Can be utilized for battery housings and thermal management systems to enhance efficiency and safety.
• Aerospace applications: Ideal for structural parts and heat exchangers that require reliable performance near engines.
• Renewable energy: Applicable for wind turbines and solar panel frames requiring durable, lightweight, and corrosion-resistant materials.

ADVANTAGES

• Enhanced high-temperature strength: Maintains performance up to 350-400 °C with minimal strength degradation.
• Superior creep resistance: Designed to mitigate grain boundary sliding, resulting in increased durability under load.
• Isotropic mechanical properties: Near-equiaxed grain structure ensures uniform performance, regardless of build direction.
• Simplified post-processing: Eliminates or minimizes the need for additional treatments, enabling immediate usability after printing.

IP STATUS
Patent Pending