BLT-AlAM500: The cutting-edge aluminium alloy designed for aerospace 3D printing

Bright Laser Technologies (BLT) recently unveiled two advanced additive manufacturing materials, including a high-strength aluminium alloy designed specifically for aerospace 3D printing applications.

About BLT-AlAM500

The BLT-AlAM500 made its debut at TCT Asia earlier this year. It aims to address challenges such as cracking and low component density often encountered in selective laser melting processes. The Chinese manufacturer claims to have optimised process parameters for high-strength aluminium alloys, particularly targeting manufacturing large, intricate components with integrated structures.

During the Shanghai event in May, BLT showcased several examples of thin-walled parts featuring internal cavities, including a bent tube, ventilation duct, and connecting pipe. These components were printed on the BLT-S400 machine in less than 30 hours and boasted an average weight reduction of approximately 20 per cent.

Following heat treatment, the material reportedly achieves impressive mechanical properties, including tensile strengths ranging from 530 to 550 MPa, yielding strengths between 480 and 500 MPa, and elongation rates from 11 to 17 per cent. Additionally, it exhibits excellent fracture toughness, boasting a room temperature value of 30.8 MPa·m1/2, and demonstrates robust fatigue performance with a high-cycle fatigue strength of 245 MPa for smooth samples.

Beyond aerospace applications, Bright Laser Technologies highlights the growing demand for high-strength aluminium alloys across diverse industries. These include high-speed trains, lightweight automotive components, and sports equipment, reflecting the material's versatility and potential for enhancing performance in various demanding environments.

BLT-Ti65 powder

Bright Laser Technologies has also unveiled its BLT-Ti65 powder, a high-temperature titanium alloy designed to excel in strength, ductility, creep resistance, corrosion resistance, and thermal stability up to 650°C. Tailored for Selective Laser Melting (SLM) and Direct Energy Deposition (DED) processes, this material targets applications in aerospace, chemical equipment, and marine industries.

The alloy's development addresses common challenges such as unmelted or partially melted powder particles, inter-track and inter-layer porosity, and cracking. These advancements aim to enhance reliability and performance in demanding operational environments where high-temperature stability and mechanical integrity are critical.

About BLT-Ti65 powder

According to Bright Laser Technologies (BLT), the BLT-Ti65 powder features a nominal chemical composition of Ti-5.9Al-4Sn-3.5Zr-0.3Mo-0.4Si-0.3Nb-2.0Ta-1.0W-0.05C. This titanium alloy is available in particle sizes of 15-53μm for Selective Laser Melting (SLM) and 75-180μm for Direct Energy Deposition (DED) processes.

After heat treatment, components fabricated with the 15-53μm BLT-Ti65 powder can achieve impressive mechanical properties at high temperatures, including yield strengths ranging from 483 to 503 MPa, tensile strengths between 604 and 624 MPa, and elongation rates from 16.5 per cent to 26.5 per cent at 650°C. Meanwhile, parts produced with the 75-180μm BLT-Ti65 powder exhibit yield strengths of 478-538 MPa, tensile strengths of 588-648 MPa, and elongation rates of 22 per cent to 32 per cent at the same elevated temperature. These attributes make BLT-Ti65 suitable for demanding applications in aerospace, chemical equipment, and marine industries, addressing challenges like inter-track porosity and ensuring robust performance under high thermal and mechanical stresses.

Earlier this year, Bright Laser Technologies (BLT) unveiled an updated version of its BLT-S450 metal laser powder bed fusion system. This upgraded model boasts a generous build envelope measuring 400 x 450 x 500 mm and offers the option of an eight-laser configuration. These enhancements are designed to optimise cost efficiency and quality and improve automation and safety in additive manufacturing processes. These developments follow a highly successful period for the company, which reported a remarkable 78 percent year-on-year increase in net profit for 2023. BLT's net income surged by 78.11 per cent compared to the previous year, resulting in profits totalling approximately 19.6 million USD.