Oak Ridge National Laboratory
08/26/2025 | News release | Distributed by Public on 08/26/2025 11:57
New DuAlumin-3D alloy enhances high-performance automotive parts
From automotive to aerospace: Versatile alloy offers superior strength, fuel efficiency
August 26, 2025
The pictured automotive piston was additively manufactured using the ORNL-developed DuAlumin-3D alloy. Credit: Amy Smotherman Burgess/ORNL, U.S. Dept. of Energy
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.
The research team 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," said 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.
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