The Technology Innovation Institute (TII), a leading global scientific research center and the applied research pillar of Abu Dhabi’s Advanced Technology Research Council (ATRC), has announced the development of AMALLOY-HT, a new metal 3D printing alloy. The new proprietary aluminium alloy powder is the Middle East’s first metal additive manufacturing feedstock designed for use in Powder Bed Fusion – Laser Beam (PBF-LB) systems.
The material is specifically designed for use in harsh environments and exhibits exceptional stability in high-temperature environments.
AMALLOY-HT – New Metal 3D Printing alloy from the Middle East
AMALLOY-HT, a ground-breaking innovation from TII’s Advanced Materials Research Centre (AMRC), successfully resolves long-standing issues in the metal additive manufacturing industry related to the use of the Powder Bed Fusion – Laser Beam (PBF-LB) technique. The method, which uses a high-energy source to melt the raw material and shape it as needed, has found widespread adoption in a variety of industry applications.
However, challenges persist due to the aggressive nature of the laser-material interaction involved in the process, which causes cracks and other manufacturing defects in a variety of materials, particularly high-strength materials.
The palette of 3D-printable high-strength metals is now expanding thanks to TII’s research and development. AMALLOY is the first low-cost, high-strength aluminium alloy designed and manufactured entirely in the UAE by a team of researchers. The AMALLOY material family has exceptional strength and an extremely low hot crack susceptibility coefficient.
The newly released, high-temperature variant of the alloy ‘AMALLOY-HT’ demonstrates excellent thermal stability, particularly in extremely high-temperature environments (up to 300°C), not long after the launch of AMALLOY. It is worth noting that the maximum operating temperature for any aluminium alloy is 300 degrees Celsius, as aluminium degrades above this temperature.
The material’s versatility and high-temperature resistance will open up new opportunities in a variety of industries, including automotive, aviation, aerospace engineering, and space exploration, as well as oil and gas and energy. AMALLOY-HT can be used to make pistons for racing cars and satellites, among other things.
“While there have been several examples of new materials for additive manufacturing emerging from laboratories in the US, Europe, and Australia, this is the first time the UAE has joined the elite list of countries with sovereign capabilities in this domain. We are now cultivating the expertise to produce metal powder and design innovative materials, empowering us to manufacture existing alloys and create new ones for both local and global markets.”
– Dr. Nesma Aboulkhair, Director of Additive Manufacturing at TII
Dr. Federico Bosio, Lead Researcher in Additive Manufacturing Materials at TII, said, “As part of TII’s ongoing commitment to innovation, AMALLOY-HT will continue to undergo refinement, fine-tuning, and even more comprehensive testing. The goal is to commercialize the high-strength aluminium alloy specifically designed for high-temperature applications. While this material creates a plethora of new opportunities and solutions for industries around the world, it will also elevate Abu Dhabi and the UAE’s reputation as a hub for cutting-edge research and development.”
AMALLOY and its new high temperature variant are expected to expand international collaboration opportunities for researchers, manufacturers, and industry leaders, allowing them to fully realise the potential of these advanced materials across domains. TII has already filed two patent applications with the United States Patent and Trademark Office for AMALLOY and AMALLOY-HT, and it intends to use its framework to develop alloys from other metal families.
