QuesTek Innovations LLC, a developer of metal alloys, has created a new aluminum (Al) alloy for additive manufacturing. This alloy is capable of high-strength performance at elevated temperatures (200° C to 300° C) in as-built condition, and is believed to be the first powdered AI material to meet those requirements without the need for subsequent heat treatment. The new alloy will enable the printing of lighter-weight precision components not currently possible with traditional manufacturing methods, such as heat exchangers or other components requiring internal cooling channels where such features are not viable to Source: QuesTek Innovations LLCobtain via machining. Because of the high-temperature strength of printed components using QuesTek’s new alloy, it will also be possible to reduce weight in parts currently made from titanium (Ti).

The new Al alloy was developed using QuesTek’s proven Integrated Computational Materials Engineering (ICME) technologies and Materials by Design approach, which combines the company’s computational technology with an exclusive stage-gate design and development process. As a global leader in the practical application of ICME, QuesTek focuses on the rapid design and development of materials, from a conceptual need through product insertion.

In an effort to explore the full potential of QuesTek’s printable Al alloy, the company will be collaborating with the German Aerospace Center (Deutsches Zentrum für Luft-und Raumfahrt, “DLR”). The DLR will print demonstration components of their design for aeronautics and space applications, and prepare a performance brief for European aerospace manufacturers. QuesTek will separately print components for a major U.S. aerospace OEM, and for Pankl Racing, an Austrian-based manufacturer known for advanced production technologies and high-performance components.

This new high-temperature Al alloy is one of a series of Al alloys for additive manufacturing QuesTek is developing along with a high-strength, at-room-temperature variant, as well as a high-strength and highly corrosion-resistant variant.

More information on QuesTek's development of aluminum alloys can be found here.