Invention Reference Number
Researchers at Oak Ridge National Laboratory have developed a novel aluminum alloy engineered for additive manufacturing that achieves a rare combination of high strength, electrical conductivity, and superior creep resistance. This alloy addressees the growing demand for advanced conductor materials in electric vehicles and other high-performance systems where lightweighting, thermal management, and durability are essential.
Description
This innovation involves a unique aluminum-based alloy composition tailored for laser powder bed fusion additive manufacturing. The alloy’s microstructure, formed under rapid solidification conditions, promotes strength while preserving high electrical conductivity. Post-fabrication heat treatments further enhance performance through controlled nanoscale precipitation. Unlike traditional materials that degrade under elevated temperatures, this alloy maintains mechanical integrity and conductivity even under stress and heat exposure. A key feature of this system is its ability to suppress creep deformation – achieving near-zero creep rates – while avoiding the typical tradeoffs between strength and electrical efficiency. The additive manufacturing process also enables complex geometries ideal for electrical and thermal performance in constrained applications.
Benefits
- Maintains electrical conductivity while achieving high mechanical strength
- Exceptional creep resistance under elevated temperature conditions
- Compatible with complex component designs via additive manufacturing
- Potential for reduced weight and enhanced performance in conductive components
Applications and Industries
- Electric vehicle components: Rotors, inverters, and busbars
- High-efficiency electrical systems and power electronics
- Aerospace and automotive lightweighting initiatives
- Energy systems requiring long-term material stability under stress
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
