AddUp Adds Constellium’s Aheadd CP1 Aluminum Alloy to Material Portfolio

AddUp has expanded its material portfolio by adding Constellium’s Aheadd CP1 aluminum alloy to its FormUp 350 machines, offering a high-performance alternative to traditional aluminum alloys for additive manufacturing (AM).

Constellium’s Aheadd CP1 alloy can now be used on AddUp FormUp 350 machines. This aluminum alloy is specially developed for the needs of AM and is said to provide an interesting alternative to traditional grades such as AS7 or AS10, with higher productivity and better performance for heat dissipation applications.

AddUp qualified the new aluminum alloy Aheadd CP1 for FormUp 350 machines. This alloy was developed by Constellium and was designed for the needs of AM by laser powder bed fusion (LPBF) specifically for high-performance and lightweight applications.

The current AM market is dominated by AS7 and AS10 grades (alloys of aluminum, silicon and magnesium, originally created for the foundry industry). Constellium offers an aluminum-iron-zirconium alloy with higher solderability which makes it possible to increase laser power and scan speed, and therefore to improve productivity. The gains can range depending on the type of part to be printed, and more could be achieved in the next years.

Above all, with Constellium alloy, post-build operations are simplified. “To obtain the best mechanical properties using AS7 and AS10 grades, several long and expensive post-build treatments must be carried out, such as hot isostatic pressing and, solution and aging, etc.,” says Frédéric Sar, Materials Officer at AddUp. “With Aheadd CP1, very similar material properties can be achieved with a simple heat treatment at 400°C.”

Saving time and money on these post-printing operations, which represent up to 40 to 50% of the cost of LPBF parts, can make a difference in the profitability of an application.

In detail, the mechanical properties of parts made by AddUp from Aheadd CP1 (particle size 20-63 micron) are close to those of AS7 in terms of hardness, at least equivalent in fatigue resistance and higher in ductility. These parts are also compatible with anodizing treatments to improve corrosion resistance.

Higher thermal conductivity of Aheadd CP1 compared to traditional aluminum alloys makes Constellium’s alloy a better candidate for heat exchanger applications. This alloy is stable up to 250°C without degrading its microstructure. Therefore, the parts made out of this material can be used at higher temperatures compared to AS7, which paves the way for lightweight applications for the aerospace industry.

All these characteristics make Aheadd CP1 a potential alternative to AS7 and AS10 alloys for 3D printing. This material was recently approved in the field of motorsports. Combining this material with performance of the AddUp FormUp 350 machine, increases the productivity without compromising the part quality. This material could quickly gain significant interest in many other industrial sectors, including aeronautics and aerospace.

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• Read about AddUp’s participation in a $1.5 million USAF Research on IN-718 additive manufacturing. AddUp is partnering with Zeda to provide critical project support to provide the USAF with a set of manufacturing guidelines to maximize the capabilities of LPBF to meet fleet readiness and sustainment goals.
   
• Read about another Addup collaboration with Zeda — this time for aerospace and medical additive manufacturing. The first of eight AddUp FormUp 350 powder bed fusion machines deployed has been installed at Zeda to support its growth in the aerospace and medical sectors.