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New aluminum alloy for 3D printing, retaining hardness at 300°C, created at NUST MISIS

Calcium in the composition replaced nickel

Scientists from NUST MISIS have developed a metallic powder based on aluminum with calcium additive. It is five times more ductile than existing analogues while maintaining comparable strength. Products made from this alloy retain their properties when heated up to 300°C, making the material promising for the aerospace, automotive, and energy industries. This is reported by the "Nauchnaya Rossiya" portal.

Image source: Grok Imagine

Why it matters

Today, silumins — aluminum-silicon alloys — are most often used for laser metal 3D printing. However, such structures quickly lose strength during prolonged heating. To increase heat resistance, nickel, cerium, or copper are added to aluminum alloys, but this increases the specific weight and cost of the material.

Researchers proposed an alternative based on the aluminum-calcium system. Calcium replaces expensive alloying elements without compromising efficiency and reduces the specific weight of the sample.

Characteristics

The samples withstand tensile loads of up to 366 MPa and can elongate by 30% without fracture. This combination of high strength and ductility allows parts to better withstand mechanical loads.

After heating to 300°C, the alloy practically does not lose hardness, whereas in traditional aluminum-silicon materials, it decreases by about a third.
Torgom Hakobyan, Senior Researcher at the Department of Metal Forming, NUST MISIS

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