Advancing Aluminium Alloys for Additive Manufacturing
The evolution of additive manufacturing (AM) has been significantly influenced by the development of advanced materials. One such material, A20X™, an aluminium-copper alloy developed by Aeromet International Ltd., has set new benchmarks in the industry. Through the High Strength Aluminium Powder for Additive Manufacture (HighSAP) project, A20X™ has demonstrated exceptional mechanical properties, making it a prime candidate for high-performance AM applications.
Understanding A20X™
A20X™ is derived from the MMPDS-approved A205 casting alloy, renowned for its superior strength and thermal stability. This alloy exhibits a refined microstructure, resulting in enhanced fatigue resistance and high-temperature performance. Such characteristics are particularly beneficial for aerospace components subjected to extreme operational conditions.
The HighSAP Initiative
Launched in 2018, the HighSAP project was a collaborative effort involving Aeromet, Rolls-Royce, Renishaw, and Phoenix Scientific Industries Ltd. (PSI). Supported by the UK’s National Aerospace Technology Exploitation Programme (NATEP), the project’s primary objective was to optimise A20X™ for additive manufacturing processes. This entailed refining atomisation techniques and establishing processing parameters to produce high-quality, AM-ready powders.
Achievements and Findings
The HighSAP project yielded remarkable results. Heat-treated components manufactured using A20X™ powder achieved an Ultimate Tensile Strength (UTS) of 511 MPa, a Yield Strength of 440 MPa, and an elongation of 13%. These metrics not only surpass the critical 500 MPa UTS threshold but also position A20X™ as one of the strongest aluminium powders available for AM. Notably, these mechanical properties are maintained even at elevated temperatures, underscoring the alloy’s suitability for demanding aerospace applications.
PSI’s Contribution
Phoenix Scientific Industries Ltd. (PSI) and sister company Metal Powder and Process Ltd (MPP) played a pivotal role in the HighSAP project by leveraging its expertise in gas atomisation. PSI’s advanced atomisation technology ensured the production of A20X™ powders with controlled particle size distribution and minimal oxidation—critical factors for consistent AM performance. Dr. Gordon Kerr of PSI noted, “PSI is very pleased to be a partner in this project, which aligns well with our strategy of optimising powders for additive manufacturing.”
In addition to its role in HighSAP, PSI is actively expanding its strategic direction to support global industrial partners in the development of novel alloy compositions and the optimisation of atomisation processes. By offering tailored support for custom powder development, PSI aims to become a long-term partner to OEMs, research institutions, and AM supply chain leaders seeking to push the boundaries of metal powder innovation. This global-facing approach is already fostering new collaborations in aerospace, energy, and advanced manufacturing.
Implications for the Aerospace Sector
The successful optimisation of A20X™ for additive manufacturing opens new avenues for the aerospace industry. Components that were previously challenging to produce using traditional methods can now be manufactured with enhanced performance characteristics. The alloy’s high strength-to-weight ratio and thermal stability make it ideal for critical aerospace parts, potentially leading to improved fuel efficiency and reduced emissions.
Conclusion
The HighSAP project’s success underscores the importance of collaborative R&D in advancing additive manufacturing materials. With A20X™ now optimised for AM, industries can look forward to producing components that meet stringent performance requirements, paving the way for innovations in aerospace and beyond. PSI’s ongoing commitment to process innovation and partnership further ensures that novel materials like A20X™ continue to evolve to meet future industrial demands.
For more information on A20X™ and its applications, visit www.a20x.com.
This article is based on information from Aeromet’s official news release: Aeromet reaches new heights with A20X™ Powder for additive manufacturing.