New material gives copper superalloy-like strength

Summary

The ARL and Lehigh researchers collaborated with scientists from Arizona State University and Louisiana State University to develop the alloy, which can withstand extreme heat without significant degradation. This and other innovative alloys will continue to be studied in Lehigh’s newly outfitted high-tech research labs, the Nanoalloy Lab and Nanoceramics Lab, which include high-pressure torsion systems, nanoindentation equipment and specialized high-temperature furnaces. Combining Copper with a Complexion-Stabilized NanostructureThe breakthrough comes from the formation of Cu₃Li precipitates, stabilized by a Ta-rich atomic bilayer complexion, a concept pioneered by the Lehigh researchers. Unlike typical grain boundaries that migrate over time at high temperatures, this complexion acts as a structural stabilizer, maintaining the nanocrystalline structure, preventing grain growth and dramatically improving high-temperature performance.The alloy holds its shape under extreme, long-term thermal exposure and mechanical stress, resisting deformation even near its melting point, noted Patrick Cantwell, a research scientist at Lehigh University and co-author of the study. By merging the high-temperature resilience of nickel-based superalloys with copper — which is known for exceptional conductivity — the material paves the way for next-generation applications, including heat exchangers, advanced propulsion systems and thermal management solutions for cutting-edge missile and hypersonic technologies.A New Class of High-Performance MaterialsThis new Cu-Ta-Li alloy offers a balance of properties not found in existing materials:Nickel-based superalloys (used in jet engines) are extremely strong but lack the high thermal conductivity of copper alloys.Tungsten-based alloys are highly heat-resistant but dense and difficult to manufacture.This Cu-Ta-Li alloy combines copper’s exceptional heat and electrical conductivity while remaining strong and stable at extreme temperatures.Whi...