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<p>Lightweight metals for additive manufacturing remain constrained by limited strength-ductility synergy, restricting their use in high-performance structural applications. Here we report a design strategy for additively manufactured alloys based on ductile-transformable eutectic nano-skeletons (DT-ENS) enabled by non-equilibrium solidification. In a near-eutectic Al-Er system, we develop an alloy family containing a deformable Al<sub>3</sub>(Er,Mg) nano-skeleton as the primary strengthening architecture. Site-specific atomic substitution and long-range chemical ordering within the&#xa0; Al<sub>3</sub>(Er,Mg) skeleton are associated with deformation twinning and the&#xa0;strain-induced&#xa0;formation of&#xa0;9R-type long-period stacking ordered structures, which enhance&#xa0;work-hardening of the skeleton&#xa0;and promote cooperative deformation with the α-Al matrix. Laser powder bed fusion yields Al-Er alloys with strengths of 600-700 MPa, together with good printability and useful ductility. These findings establish a new benchmark for structural additively manufactured aluminium alloys, provide a route for developing ductile intermetallics to overcome the&#xa0;strength-ductility&#xa0;trade-off in high-strength aluminium alloys, and demonstrate the role of additive manufacturing in uncovering new alloy systems and deformation mechanisms.</p>

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Strong 3D-printed aluminium reinforced with ductile-transformable eutectic nano-skeleton

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年4月25日

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  • Yang Li,
  • Tingting Chen,
  • Shengyi Zhong,
  • Haixing Fang,
  • Pucong Sheng,
  • Siming Ma,
  • Han Chen,
  • Yuchi Cui,
  • Gang Ji,
  • Yihao Wang,
  • Yirui Chang,
  • Lei Hu,
  • Mingliang Wang,
  • Shixin Nie,
  • Haowei Wang,
  • Zhe Chen

摘要

Lightweight metals for additive manufacturing remain constrained by limited strength-ductility synergy, restricting their use in high-performance structural applications. Here we report a design strategy for additively manufactured alloys based on ductile-transformable eutectic nano-skeletons (DT-ENS) enabled by non-equilibrium solidification. In a near-eutectic Al-Er system, we develop an alloy family containing a deformable Al3(Er,Mg) nano-skeleton as the primary strengthening architecture. Site-specific atomic substitution and long-range chemical ordering within the  Al3(Er,Mg) skeleton are associated with deformation twinning and the strain-induced formation of 9R-type long-period stacking ordered structures, which enhance work-hardening of the skeleton and promote cooperative deformation with the α-Al matrix. Laser powder bed fusion yields Al-Er alloys with strengths of 600-700 MPa, together with good printability and useful ductility. These findings establish a new benchmark for structural additively manufactured aluminium alloys, provide a route for developing ductile intermetallics to overcome the strength-ductility trade-off in high-strength aluminium alloys, and demonstrate the role of additive manufacturing in uncovering new alloy systems and deformation mechanisms.