(ORNL: Oak Ridge, TN) -- Scientists at Oak Ridge National Laboratory have advanced the use of DuAlumin-3D, an innovative aluminum alloy, in high-temperature automotive components, significantly expanding the possibilities of additive manufacturing.

Research found that DuAlumin-3D outperforms traditional alloys, which are prone to cracking during laser powder-bed fusion processing, while maintaining comparable heat characteristics. This advancement offers lightweighting solutions and reduces fuel costs.

“DuAlumin-3D performed exceptionally well in our evaluations,” says lead ORNL researcher Alex Plotkowski. “While our research focused on its use in high-efficiency engines, it could also be used for lightweighting applications in aerospace and to optimize heat exchangers.”

The ORNL-developed alloy exhibits superior strength and resistance to deformation at elevated temperatures, outperforming all known aluminum alloys. This automotive piston was additively manufactured using the ORNL-developed DuAlumin-3D alloy. Credit: Amy Smotherman Burgess/ORNL, U.S. Dept. of Energy