The global aerospace and defence sectors are constantly evolving, with propulsion technologies at the forefront of innovation. In this context, aluminium-lithium (Al-Li) metal powders have emerged as a transformative material for solid rocket and missile propellants. These advanced powders offer exceptional performance characteristics that significantly enhance fuel energy density, efficiency, and mission capability. A notable development effort in this field has been undertaken by Metal Powder & Process (MPP), a sister company to PSI, which collaborated closely with Adranos (now owned by Anduril Industries), a leading developer of next-generation solid rocket propellants, to perfect the production method for Al-Li powders. This collaboration resulted in a year-long development program culminating in a breakthrough atomisation technology tailored for these high-performance materials.
The Strategic Value of Aluminium-Lithium in Propellants
Aluminium has long been used in solid rocket propellants due to its high energy release during combustion. Lithium, on the other hand, has an even higher specific energy and burns more cleanly, producing less slag and residue. When combined, aluminium-lithium alloys offer a synergistic effect, delivering:
- Higher specific impulse compared to conventional aluminium-based fuels.
- Reduced exhaust byproducts, contributing to cleaner combustion.
- Improved efficiency in both tactical and space propulsion systems.
These qualities make Al-Li powders ideal for use in hypersonic vehicles, missiles, and orbital launch systems, where maximising energy output while minimising system weight is critical.
MPP’s Role in Advanced Al-Li Powder Development
In response to Adranos’ demand for a reliable, high-quality aluminium-lithium powder suitable for their proprietary ALITEC propellant formulation, MPP launched a comprehensive year-long development program. This initiative focused not only on refining the alloy composition but also on solving one of the most significant technical challenges: the atomisation of aluminium-lithium—a reactive and lightweight alloy that is notoriously difficult to process using conventional techniques.
Working in tandem with Adranos’ engineering and materials teams, MPP developed a novel atomisation process specifically optimised for Al-Li alloys. The new technology:
- Enables precise control of particle size distribution and morphology, essential for predictable combustion behaviour.
- Incorporates inert atmosphere controls to prevent oxidation and lithium loss during processing.
- Achieves exceptional yield and purity, ensuring the powder meets strict aerospace-grade specifications.
The process innovation also supports scalable production, a key requirement as Adranos moves from prototyping to full-scale manufacturing of its ALITEC-powered systems.
Technical Challenges and Breakthroughs
Developing Al-Li powders for propulsion applications presented multiple hurdles:
- Reactivity: Lithium’s high chemical reactivity required sophisticated inert gas handling during melting and atomisation.
- Density control: Ensuring uniform distribution of lithium in the aluminium matrix was essential to prevent segregation and inconsistencies in burn performance.
- Process integration: Adapting the atomisation line to handle the alloy safely and efficiently necessitated both hardware and software innovations.
MPP’s new system, designed specifically for low-density, high-reactivity materials, represents a first-of-its-kind platform for scalable aluminium-lithium powder production. PSI now have a world-leading atomisation platform for reactive materials.
Adranos and the Future of ALITEC Propellant
Adranos has gained national and international attention for its ALITEC solid propellant, which incorporates aluminium-lithium powder to achieve superior performance compared to traditional aluminised fuels. The success of the MPP Al-Li powder development program provides a critical supply chain backbone, enabling Adranos to accelerate testing, integration, and delivery of propulsion systems for a range of defence and space applications.
With MPP’s advanced atomisation process, Adranos now has access to a reliable, high-performance propellant material that supports its mission to revolutionise solid rocket propulsion.
Conclusion
The collaboration between Metal Powder & Process (MPP) and Adranos marks a significant milestone in the production and application of aluminium-lithium metal powders for aerospace propulsion. Through an intensive development program and the creation of specialised atomisation technology, MPP has delivered a solution that meets the stringent demands of modern missile and rocket systems.
As defence and space programs seek ever-higher performance and efficiency, the innovations made in aluminium-lithium powder technology stand to play a central role. This advancement not only strengthens the capabilities of companies like Adranos but also underscores MPP’s position at the cutting edge of powder metallurgy for strategic and high-impact applications.
Learn More
To explore partnership opportunities or discuss how our proprietary aluminium-lithium powders can support your next-generation propulsion program, contact MPP today. We’re ready to help you take innovation to the next level.
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