Alcoa invests 60 million U.S. dollars to enhance additive manufacturing R&D capabilities

Recently, Alcoa will invest 60 million U.S. dollars to expand its R&D center in Pennsylvania, aiming to accelerate the development of advanced 3D printing materials and processes. Alcoa's materials scientists will produce special aluminum, titanium and nickel powders for the 3D printing process. These powders will be customized for a variety of additive manufacturing processes to produce stronger 3D printed parts and meet other quality and performance requirements. Designed to meet the growing demand for complex, high-performance 3D printed parts in the aerospace, automotive, and medical industries.

“Alcoa is investing in the next generation of 3D printing technologies for aerospace and other industries,” said Alcoa Chairman and Chief Executive Officer, “combining our expertise in metal alloys, manufacturing, design and product quality certification. Alcoa will break through the limits of current additive manufacturing technologies. This investment reinforces our leadership in meeting the rapidly growing demand for additive manufacturing technology for aerospace components.”

In addition, Alcoa also disclosed a new process called Ampliforge, which combines advanced materials, design, additive manufacturing technologies, and traditional manufacturing processes. Alcoa uses this process to design and 3D print an almost complete part, which is then processed using traditional manufacturing processes such as forging. The company stated that this method can improve the performance of 3D printed parts, for example, increased toughness and strength compared to parts produced only through additive manufacturing techniques. In addition, the Ampliforge process significantly reduces material use and simplifies the production process compared to traditional forging processes.

The additive manufacturing research conducted by Alcoa Inc. mainly includes:

Advanced Materials Research: Alcoa will develop aluminum powder, titanium powder and nickel powder for additive manufacturing. These materials will be tailored to a variety of additive manufacturing processes to produce stronger-strength additive manufacturing components and meet their quality and performance requirements.

The combination of process and design: Alcoa will further develop advanced 3D printing design and manufacturing technologies, such as Alcoa's Ampliforge process, to increase production speed, reduce costs, and create geometric structures that traditional processes cannot achieve.

Qualification and Certification: Alcoa will use its expertise in testing and process control to start with the aerospace industry and certify new 3D printed parts.