Surface treatment and alloy development to reduce weight of AM aluminium parts

Purpose and goal

The purpose of this project is to increase the use of high-strength aluminum alloys in load-bearing parts manufactured by additive manufacturing. By replacing titanium alloys with high-strength aluminum alloys in topology-optimized lightweight structures, there is the great potential for significant weight and energy savings. However, this requires further studies on surface treatment for corrosion protection and alloy development of high-strength aluminum alloys adapted for additive manufacturing.

Expected results and effects

- An increased use of high-strength aluminum alloys for additive manufacturing (AM). - At least 20% weight loss when Ti alloys are replaced with Al alloys in topology-optimized AM parts. This material change is also expected to provide significant energy savings in the recycling of AM parts. - Reduced costs by at least 20% by eliminating the need for scandium or other exotic alloying elements in high-strength aluminum alloys for AM. These alloys will also ensure a continued high recycling rate for aluminum alloys.

Planned approach and implementation

WP - Alloy development: A cost-effective screening method that does not require any atomization of the alloy will be utilized to check a large number of potential alloys with different alloying elements and compositions. Later the selected alloys will go through the normal AM route for further evaluation. WP - Anodization processes: The anodization process and corrosion resistance for commercially available high strength AM alloys and the new alloys will be evaluated. WP - Characterisation: Microstructure and mechanical properties will be evaluated.