The Innovative Manufacturing Cooperative Research Centre (IMCRC) has announced the commercialisation of a novel high-strength aluminium wire that could transform the way complex metal objects are manufactured.
Designed for welding and 3D printing applications, the new welding wire is the result of IMCRC’s research and development collaboration with Wire Additive Manufacturing developer AML3D and Deakin University’s Institute for Frontier Materials (IFM).
The product is set to undergo further development, including tests against industry standards, as AMl3D and IMCRC work towards commercialisation.
The project began in 2021 to address AML3D’s need for a high-strength aluminium welding wire to use in 3D printing that required minimal or no heat treatment after the manufacturing process.
“Our patented Wire Additive Manufacturing (WAM®) 3D metal printing process can produce medium to large objects. However, the aluminium alloys we currently use require up to 24 hours of heat treatment to reach optimum strength, which can be costly and creates some logistical challenges,” said Andy Sales, ALM3D’s executive director and chief technical officer.
According to Sales, the partnership has enabled AML3D to develop a cost-effective, high-strength aluminium alloy wire that requires just 30 minutes of heat treatment once printed.
“By supporting the project and facilitating the introduction to IFM, IMCRC has helped change the trajectory of our business, expanding our potential customer base and creating further opportunities to innovate through R&D,” said Thomas Dorin, a senior research fellow at IFM.
“We were pleased to work with AML3D and IMCRC on this ambitious project, which encompassed over 20 different compositions and iterations. Our chosen alloy, a mixture of aluminium, magnesium and scandium, has recently been patented, and we’ve also commenced commercial production,” Dorin added.
The project will undergo its next phase, which involves printing products to demonstrate the wire’s potential applications.
IFM will also work closely with AML3D to show shipbuilders how they can print directly at the shipyard, enabling an effective way to reduce material waste and streamline logistics.
David Chuter, CEO and managing director of IMCRC, said by creating an alternative to traditional processes like subtractive manufacturing, AML3D has paved the way towards enhancing the adoption of more innovative manufacturing techniques.
“Making the manufacture of metal parts more efficient, cost-effective and timely is critical to helping Australia’s manufacturing sector become more competitive and attractive, which will encourage customers to bring production onshore,” Chuter said.
