Metalysis manufactures Al₃Sc powder with a high scandium content and is also targeting additive manufacturing

Metalysis has launched commercial production of a high-scandium aluminum–scandium alloy powder (Al₃Sc). According to the company, the trigger is growing demand for non-Chinese sources of critical raw materials, intensified by China’s recent export controls on rare earths. The material initially targets semiconductor manufacturers, but in powder form it is also of interest for 3D-printing applications where reproducible alloy chemistry and low impurities are critical.

Technically, Metalysis positions the powder as a “master alloy” with a current 36 wt% scandium, or 25 at% scandium. The specification lists very low levels of oxygen (500 ppm) and carbon (50 ppm). Such parameters are particularly relevant when the powder is used either to produce consolidated targets for thin-film deposition or to be further processed in powder-metallurgical process chains. Metalysis offers the material both as powder and as densified discs and points to spark plasma sintering and hot-pressing trials carried out together with RHP-Technology, in which densities of more than 98% were reportedly achieved.

In its manufacturing process, Metalysis does not rely on conventional melting, but on the FFC Cambridge electrolysis approach. In this process, scandium oxide and aluminum oxide are jointly reduced in a calcium chloride melt at 650 to 950°C, which, according to the company, promotes a fully homogenized alloy with consistent properties.

“Scandium alloys are increasingly replacing titanium and legacy aluminium alloy components in DoD systems due to their superior lightweight, high-strength characteristics”, Dr. Vic Ramdass, Acting Assistant Secretary of Defense for Industrial Base Policy.

For aerospace and defense, Metalysis also envisages lower scandium contents, which customers can set by dilution.

Nitesh Shah, CEO: “Metalysis has a clear strategy focused on premium critical materials. Our aluminium scandium alloy is fully homogenised and extremely low in impurities, making it ideal for high-performance applications in semiconductor manufacturing, whilst defence and aerospace manufacturers are exploring applications of lower scandium loadings.   The recent REE export controls from China have accelerated urgent adoption of our aluminium scandium alloys, and we are now scaling production to meet this demand, moving from our Gen 2 units today to tonne-scale output from Gen 3 in the coming months.”