APWORKS launches new Scalmalloy CX

APWORKS‘ newest material, Scalmalloy CX, represents a significant advancement in material science, particularly for cryogenic temperature applications. This second (or third) generation material is designed to maintain exceptional mechanical properties even at extremely low temperatures, making it a game-changer for industries such as aerospace, where performance and weight are critical factors.

Scalmalloy CX: origins

Scalmalloy CX is the newest member of the Scalmalloy family, a series of advanced aluminum-magnesium-scandium (AlMgSc) alloys originally developed by Airbus Group. The original material, Scalmalloy RP, was created specifically for rapid prototyping and manufacturing using what Airbus referred to as “additive layer manufacturing (ALM) processes”. This material displayed high strength in layer-wise-generated 3D parts, offering nearly double the strength of traditional aluminum powders used in selective laser melting (SLM).

The Scalmalloy alloy family, including Scalmalloy RP, has been a cornerstone of APWORKS’ efforts to provide tailorable material solutions with exceptional fatigue and toughness properties. The success of Scalmalloy RP in various applications, such as aerospace, automotive, and robotics, laid the groundwork for the development of Scalmalloy CX. The goal was to create a material that not only retained the benefits of its predecessors but also excelled in cryogenic environments, where conventional materials often fail.

Features and advantages of Scalmalloy CX

Scalmalloy CX is designed to maintain superior fracture toughness and ductility at temperatures as low as 22K (-251°C). This makes it ideal for cryogenic applications, particularly in industries where weight reduction is as critical as performance.

The hallmark of Scalmalloy CX is its ability to withstand the extreme stresses encountered at cryogenic temperatures without compromising structural integrity. This is crucial for applications like liquid hydrogen storage and pumping, where material failure can have catastrophic consequences.

Scalmalloy CX also exhibits high ductility even at low temperatures, allowing it to endure the dynamic stresses present in cryogenic environments. This property is particularly valuable in hydrogen propulsion systems, where materials are subjected to intense thermal and mechanical loads.

One of the standout features of Scalmalloy CX, inherited from the original Scalmalloy RP, is its low density. This characteristic is especially beneficial for aerospace applications, where every gram saved can translate into significant performance gains. In comparison, traditional stainless steel components used in cryogenic applications are much heavier, making them less suitable for cutting-edge aerospace technologies.

While Scalmalloy CX is a general-purpose material for cryogenic applications, it was specifically developed with hydrogen propulsion technologies in mind. As the aerospace industry moves towards cleaner, more efficient propulsion systems, the need for lightweight, high-performance materials has never been greater. Scalmalloy CX meets this need by offering a material that is both lightweight and capable of withstanding the demands of liquid hydrogen storage and transportation.

Impact on hydrogen propulsion

Hydrogen propulsion represents the future of aerospace, offering a cleaner, more efficient alternative to traditional fossil fuels. However, the success of hydrogen propulsion depends heavily on the materials used in storage and delivery systems. Scalmalloy CX is poised to play a critical role in this domain.

The low density and high strength of Scalmalloy CX make it an excellent material for components in hydrogen propulsion systems, where weight reduction is essential. By replacing heavier stainless steel components with Scalmalloy CX, aerospace engineers can achieve significant weight savings, leading to improved fuel efficiency and longer flight ranges.

In particular, the use of Scalmalloy CX in liquid hydrogen storage tanks and pumps offers a significant advantage. Traditional materials like stainless steel, while reliable, add unnecessary weight, which can hinder the performance of hydrogen-powered systems. Scalmalloy CX, on the other hand, offers the same reliability with a fraction of the weight, making it an ideal choice for these applications.

Made with Karlsruhe Institute of Technology (KIT)

For the development of Scalmalloy CX, APWORKS worked closely with the Karlsruhe Institute of Technology (KIT) to validate the material’s properties under cryogenic conditions. KIT’s contributions were instrumental in ensuring that Scalmalloy CX could meet the rigorous demands of real-world applications. Their research and testing, presented at the International Cryogenic Engineering Conference (ICEC) and the International Cryogenic Materials Conference (ICMC), provided valuable insights that guided the material’s development.

This collaboration highlights the importance of industry-academia partnerships in advancing material science. By leveraging the expertise of both APWORKS and KIT, Scalmalloy CX was able to undergo the extensive testing necessary to confirm its suitability for critical applications.

One of the key advantages of the Scalmalloy family, including Scalmalloy CX, is its compatibility with 3D printing technologies. Metallic 3D printing allows for unparalleled design freedom, enabling the creation of complex geometries that were previously unattainable with traditional manufacturing methods.

Scalmalloy materials, when combined with metal 3D printing, can lead to the development of components with enhanced functionality and reduced weight. This is particularly important in aerospace, where every gram counts. By incorporating practices such as topology optimization and bionic designs, engineers will fully exploit the potential of Scalmalloy CX to create parts that are not only lighter but also stronger and more resilient.

Future applications

The introduction of Scalmalloy CX opens up new possibilities across various industries. While its primary focus is on cryogenic applications in aerospace, the material’s unique properties make it suitable for a wide range of uses, from space exploration to medical technologies and energy storage.

As industries continue to push the boundaries of what is possible, materials like Scalmalloy CX will be at the forefront, enabling the development of lighter, more efficient, and more sustainable solutions. Its successful integration into hydrogen propulsion systems could pave the way for further innovations in clean energy, helping to reduce the environmental impact of transportation and other industries.