Scientists at NUST MISIS have developed an aluminum composite for additive manufacturing that combines lightness, high strength, and radiation resistance. The material has already passed initial tests and is ready for use in complex-shaped parts for the aerospace and nuclear industries.
Russian researchers have solved a key problem of metal composites: the uniform distribution of nanoparticles in an aluminum matrix.
Thanks to a two-stage technology using low-energy planetary ball milling, it was possible to obtain silumin powder with the addition of 1% tungsten carbide, while maintaining the flowability and density critical for 3D printing.
The tensile strength of the new material reaches 400 megapascals with an elongation of about 4% — indicators comparable to the best global analogues based on silumin. In parallel, samples are being tested for radiation resistance: irradiation with krypton ions with an energy of 147 megaelectronvolts simulates the extreme conditions of long-term operation in reactors and in orbit.
In the 3D printing process, new phases are formed in the composite: metastable beta-tungsten and an intermetallic compound of aluminum with tungsten. It is they that strengthen the alloy, allowing to combine three key properties: light weight, increased mechanical strength, and protection against ionizing radiation.
The new composite allows printing parts of complex geometry. This opens the way to creating lightweight components for satellites, rocket engines, nuclear reactor elements, and other high-tech equipment where mass, reliability, and radiation resistance are critical simultaneously.