Scalmalloy is a high-performance aluminum-magnesium-scandium alloy developed specifically for additive manufacturing, delivering strength levels that exceed all conventional aluminum alloys produced by AM and most wrought aluminum alloys. The addition of scandium to the aluminum-magnesium base produces a fine stable Al3Sc precipitate dispersion that provides both precipitation strengthening and grain refinement during rapid solidification. The combination of high strength-to-weight ratio, good ductility, and corrosion resistance makes Scalmalloy ideal for aerospace structural components, racing car chassis and suspension elements, and other weight-critical applications where aluminum’s density advantage must be combined with structural performance approaching that of titanium. Scalmalloy enables the production of complex geometries including organic lattice structures, topology-optimized brackets, and thin-wall assemblies that are impractical with conventional aluminum forming processes. Forms: ingot and waffle for powder production.
Available Forms
Ingot, Waffle
Technical Info
Thermal Properties
Melting Point (Solidus)1,100°F (593°C)
Melting Point (Liquidus)1,436°F (780°C)
Physical Properties
Density (imperial)0.096 lbs/in³
Density (metric)2.66 g/cm³
Primary ElementsAl · Mg · Sc
Lead FreeYes
Key Features
Highest Strength AM Aluminum AlloyScandium Grain RefinementAerospace and Motorsport GradeGood Weldability
Nominal Composition
Mg 4%
Sc 0.7%
Mn 0.5%
Al Bal
Frequently Asked Questions
Common technical inquiries regarding Scalmalloy
Scandium forms Al3Sc precipitates during solidification and post-build aging that are coherent with the aluminum matrix and highly resistant to coarsening at elevated temperature. These precipitates simultaneously refine the as-solidified grain structure and provide precipitation strengthening that increases yield strength by 50-100% compared to standard AM aluminum alloys. The fine grain structure also improves ductility and fatigue resistance, making Scalmalloy superior to AlSi10Mg in nearly all mechanical property categories.
Scalmalloy is typically aged at approximately 572F (300C) for 4 hours after LPBF build to maximize the Al3Sc precipitation strengthening response. This aging step increases yield strength and hardness from the as-built condition by completing the precipitation of Al3Sc particles that nucleated during rapid solidification. Unlike AlSi10Mg, Scalmalloy does not require solution annealing before aging because the rapid solidification of LPBF already produces a fine supersaturated microstructure ready for direct aging.
Demonstrated aerospace applications include satellite structural brackets, UAV airframe components, antenna support structures, and spacecraft hardware where the combination of low density and high strength reduces launch mass. In motorsport, Scalmalloy is used for Formula 1 and endurance racing components including suspension uprights, gearbox casings, and aerodynamic brackets where topology optimization combined with AM production delivers weight reductions of 30-50% versus conventionally machined aluminum parts.
