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<p>Aluminum (Al) alloys are pivotal structural materials, indispensable for advanced energy-saving solutions and lightweight technologies. However, the limited heat resistance and low critical strength of the present commercial Al alloys at elevated temperatures (300–400 °C) have constrained their broader applications. Here, we present a facile strategy to additively manufacture strong yet ductile heat-resistant Al alloys using laser powder bed fusion (PBF-LB). By embedding heat-resistant multicomponent intermetallic nanophases (HMINPs) at the solidified cell boundaries, the as-printed alloy forms thermally stable cellular structures containing a high-volume fraction (~14 vol%) of HMINPs. Without any additional post-treatment, our as-printed Al alloy exhibits an average room-temperature tensile strength of 582 MPa, combined with a tensile strength of 114 MPa and exceptional creep resistance at 400 °C. The partial solid-state amorphization of the HMINPs during tensile straining at 300–400 °C creates a nano-dual-phase glass–crystal structure, providing an additional toughening mechanism. This HMINP strategy and PBF-LB’s freeform manufacturing capability enable large-scale industrial use of our high-performance Al alloy, holding great promise for advancing energy efficiency, carbon neutrality, and sustainable manufacturing.</p>

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Strong yet ductile heat-resistant aluminum alloy by additive manufacturing

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年4月15日

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  • Gan Li,
  • Yuhe Huang,
  • Chunlu Zhao,
  • Xi He,
  • Shuo Wang,
  • Qiyang Tan,
  • Ying Li,
  • Fucong Lyu,
  • Guanghui Feng,
  • Junhua Luan,
  • Wanqian Hu,
  • Zhenmin Li,
  • Xinggang Li,
  • Yanjin Xu,
  • Yuansong Zeng,
  • Zhiqiang Li,
  • Xinping Mao,
  • Ming-Xing Zhang,
  • Lehua Qi,
  • Qiang Zhu,
  • Jian Lu

摘要

Aluminum (Al) alloys are pivotal structural materials, indispensable for advanced energy-saving solutions and lightweight technologies. However, the limited heat resistance and low critical strength of the present commercial Al alloys at elevated temperatures (300–400 °C) have constrained their broader applications. Here, we present a facile strategy to additively manufacture strong yet ductile heat-resistant Al alloys using laser powder bed fusion (PBF-LB). By embedding heat-resistant multicomponent intermetallic nanophases (HMINPs) at the solidified cell boundaries, the as-printed alloy forms thermally stable cellular structures containing a high-volume fraction (~14 vol%) of HMINPs. Without any additional post-treatment, our as-printed Al alloy exhibits an average room-temperature tensile strength of 582 MPa, combined with a tensile strength of 114 MPa and exceptional creep resistance at 400 °C. The partial solid-state amorphization of the HMINPs during tensile straining at 300–400 °C creates a nano-dual-phase glass–crystal structure, providing an additional toughening mechanism. This HMINP strategy and PBF-LB’s freeform manufacturing capability enable large-scale industrial use of our high-performance Al alloy, holding great promise for advancing energy efficiency, carbon neutrality, and sustainable manufacturing.