Additive Manufacturing with Aluminum Matrix Composites

Gamma Alloys offers high performance aluminum matrix composites for additive manufacturing. We supply powder, bar and wire forms for a variety of additive technologies such as powder bed fusion, friction stir additive deposition and wire-feed systems. The aluminum matrix can be reinforced by micron-sized as well as nano-sized ceramic particles. Our commercial size billets have been 100 and 200 Kg sizes. Recently we have been working with a solid-state friction stir additive manufacturing process that has produced materials with tensile properties that are comparable to the wrought counterparts. We have demonstrated processes that by-pass the billet manufacture and the primary extrusion processes and makes material directly from powders. In powder bed fusion additive process, the addition of nanoparticles “unlocks” metals that are previously unprintable. By introducing nano-sized spherical ceramic particles, we can improve the weldability of common aluminum alloys and reduce the susceptibility to hot tearing. A uniform dispersion of ceramic nanoparticles enhances matrix stiffness and strength at both room temperature and elevated temperature. Gamma Alloys’ powder technology can be applied to most aluminum alloys including AlSi10Mg, 2024, 6061, 5083 and 7075 aluminum. In this talk, we will demonstrate printability, microstructure and mechanical properties of 3D printed parts using our proprietary materials.