A205/F1 the powder derived from the A20X™ alloy and officially approved by FIA regulations

Zare can provide two new powders for metal 3D printing technology: A205 and A205/F1 developed with the specific purpose of being used in FIA competitions. Both powders are atomised starting from the aerospace approved A20X™ alloy.

The A20X™ story

At the end of the 1990s a group of English foundries set itself the goal of exceeding the performance allowed by casting the A201 aluminium/copper alloy.
This alloy became extremely popular for advanced aerospace engineering applications but was prone to micro-cracks and porosity when casting parts of complex shapes.

Aeromet's metallurgical experience and links with academic institutions enabled the group to begin a development project that led to the creation of a unique and entirely new aluminium alloy.

A20X™ consists mainly of aluminium and copper to which titanium diboride has been added to improve the casting process and guarantee an ultra-fine microstructure.
A20Xtm is one of the strongest lightweight alloys in the world and can be used at higher temperatures than other aluminium alloys.

Metal AM

A20X™ powder for additive manufacturing

Over the last few years, the A20Xtm alloy has been adapted and atomised to be used in powder bed systems using DMLS / SLM technology.

The excellent properties of resistance to high temperatures, corrosion and fatigue make it ideal for the production of final parts in extremely demanding sectors. A20X™ powder has made it possible to create parts with a UTS of up to 511 MPa and over 13% elongation.

A205: the lightweight aluminium powder certified for the aerospace sector

The alloy offers exceptional high temperature and fatigue strength properties, is certified for aerospace use (AMS 4417 and AMS 4482A) and is already used in the defence and automotive sectors.

Unlike other commonly used aluminium alloys, A205 does not experience significant loss of mechanical properties at an operating temperature above 125°C and has twice the strength of an Al-Sc alloy at 200°C.

Elevated temperature tensile Properties Tensile Strength Yield Stress Elongation
20°C 511 MPa 445 MPa 11%
100°C 423 MPa 375 MPa 10%
150°C 369 MPa 354 MPa 20%
200°C 331 MPa 311 MPa 15%
250°C 224 MPa 215 MPa 12%

The fatigue strength of specimens made with A205 powder display properties similar to cast A20X alloy and superior to A357 (AlSi7Mg) castings.

Data-Sheet A205

A205/F1: the aluminium powder approved by FIA

The A205/F1 Al-Cu-TiB2 alloy, much like its twin A205, lets you achieve a high-density microstructure and resistance to high temperatures, corrosion and fatigue.

A205/F1's formulation has been modified with regard that of A205 to comply with current FIA regulations regarding the use of metal matrix composites (MMC).
The alloy has been used in numerous applications including extreme motorsport.

The F1 regulation compliant formulation behaves very similarly to A205 powder, indicating that there are no significant losses of mechanical properties even with operating temperatures above 125°C.

Elevated temperature tensile Properties Tensile Strength Yield Stress Elongation
20°C 511 MPa 445 MPa 11%
100°C 423 MPa 375 MPa 10%
150°C 369 MPa 354 MPa 20%
200°C 331 MPa 311 MPa 15%
250°C 224 MPa 215 MPa 12%

Fatigue strength properties are also almost in line with the A205 alloy, as seen by tests both at room temperature and at 230°C.

Additive manufacturing is a complex process where each phase must be meticulously prepared and carried out always taking into consideration the production as a whole and the result to be achieved.

Choosing the best material for the intended application is just one of the phases. The specialised technicians at Zare, our Additive Team, are able to offer expert advice both on the process as a whole and every single phase, fully exploiting the properties of the materials and combining them in the best possible way with the advantages offered by the various 3D printing technologies available.