ORNL Develops DuAlumin-3D Alloy to Overcome Cracking in Aluminum 3D Printing

By on September 9th, 2025 in news, research

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Part 3D printed in DuAlumin-3D aluminum alloy [Source: Amy Smotherman Burgess/ORNL, U.S. Dept. of Energy]

Oak Ridge National Laboratory scientists have developed a new aluminium alloy for additive manufacturing.

The new metal is named “DuAlumin-3D”, as it is targeted for additive manufacturing processes.

What makes this metal better than current aluminium alloys? The issue is that many aluminium alloys currently used in LPBF metal 3D printing tend to crack due to thermal stress during printing and afterwards.

The new DuAlumin-3D material is more resistant to cracking, as it has “superior strength” and has resistance to deformation at higher temperatures.

ORNL researcher Alex Plotkowski explained:

“DuAlumin-3D performed exceptionally well in our evaluations. 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 new material would be particularly beneficial in the aerospace industry, where the lightweight aluminium material could be used in more parts than is currently done.

Via ORNL

By Kerry Stevenson

Kerry Stevenson, aka "General Fabb" has written over 8,000 stories on 3D printing at Fabbaloo since he launched the venture in 2007, with an intention to promote and grow the incredible technology of 3D printing across the world. So far, it seems to be working!