Researchers from Carnegie Mellon University and the Massachusetts Institute of Technology (MIT) have discovered a new aluminum alloy system that could change the way cars are built.
This innovative material, designed using advanced computer simulations and optimization techniques, combines high strength with lower costs, making it a promising choice for the automotive industry.
Aluminum alloys are already popular in car manufacturing because they are lightweight and strong.
However, when it comes to parts that need to withstand high temperatures—like engine pistons, jet engine fan blades, and vacuum pumps—traditional aluminum alloys often fall short.
At elevated temperatures, many aluminum alloys struggle to block dislocation movements, which are critical for maintaining strength.
For this reason, car manufacturers sometimes turn to titanium alloys, like Ti-64, for stronger applications. But titanium is heavier, more expensive, and difficult to work with, adding to manufacturing costs.
Additive manufacturing (AM), also known as 3D printing, is changing that. This technology allows engineers to create complex metal parts layer by layer, opening up new possibilities for material design.
In this latest research, the team identified a new aluminum alloy system that balances strength and cost more effectively. The alloy, called Al-Ni-Er-Zr-Y, is made of aluminum, nickel, erbium, zirconium, and yttrium.
According to the study, this new material can achieve 95% of the strength of the best printable aluminum alloys currently available, while cutting costs by 15%.
The researchers also created another alloy for room-temperature applications that matches the strength of existing alloys but with an 80% reduction in cost.
This breakthrough could mean cheaper, stronger car parts that are still lightweight, potentially improving fuel efficiency and reducing manufacturing expenses.
One of the key reasons this alloy is so effective is the way it is produced. The team used high-throughput calculated phase diagram (CALPHAD) simulations combined with machine learning to study how different combinations of elements affect the material’s properties.
This method allowed them to quickly identify the best mix of metals for strength and cost. Furthermore, laser-based additive manufacturing enables faster cooling during the printing process, creating unique microstructures that enhance the alloy’s strength.
Assistant Professor Mohadeseh Taheri-Mousavi, who co-led the study with doctoral student Benjamin Glaser, believes that this new aluminum alloy could make a real difference in the automotive industry.
The alloy’s improved strength and lower cost could pave the way for more sustainable and affordable car manufacturing.
The findings were published in the Journal of the Mechanics and Physics of Solids, marking an important step forward in materials science and automotive design.
