News: Metalysis achieves commercial specification of space alloy
Metalysis, the Rotherham-based end-to-end manufacturer of solid-state metal and alloy powders, and global leader in materials science, has produced C-103 alloy powder for high-demand markets such as and defence, medical, semiconductor and energy.
The company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham it also operates a site at Manvers.
The current C-103 market is estimated at $46m, reaching $200m by 2032 as users search for alternative, secure and consistent supply of this high-performance refractory alloy for use within their high temperature and extreme environment applications.
The benefits of the Metalysis electrolysis process are that in contrast to traditional melting processes for metal alloy powder production, electrolysis uses much lower temperatures and less energy and is a single-stage process rather than multi-stage, such as titanium alloy production. Also, no hazardous chemicals are used during the Metalysis process. This gives substantial energy and yield savings and means that sustainability is built-in across the Metalysis production process.
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The Metalysis process in contrast to melting is also highly adaptable, so bespoke materials can be produced as directed by specific customer demand.
C-103 alloy is one of the most widely used niobium alloys. Niobium’s melting point of 2477 degrees Celsius, excellent corrosion resistance and high strength to weight ratio ensures it is a metal of choice for critical sectors.
C-103 faces supply chain vulnerability primarily because of shortages in Hafnium metal (as opposed to hafnium oxide) production, as competing demand from other hafnium compounds has increased, driven by the rapid expansion of semiconductor chip manufacturing.
Demand is also set to increase also following recent advances in additive manufacturing (AM - 3D printing). The ability to manufacture complex C-103 structures and geometries with minimal material waste addresses one of the historical manufacturing challenges pertaining to C-103, reducing costs and lead times.
Nitesh Shah, CEO of Metalysis, said: "Metalysis is adding C-103 niobium hafnium titanium alloy to its product suite given our core focus on refractory alloys – combined with lightweighting expertise. C-103 was developed in the 1960s but now we are seeing a huge surge in demand because of the renewed race for space – as well as advanced manufacturing sectors such as hypersonics / defence.
"The Metalysis FFC process is able to produce C-103 alloy to the morphology required by AM partners – whilst reducing metal oxides rather than metal means we are not constrained by the availability of hafnium metal. Our engagement with customers in this sector has already been highly encouraging.”
In March Metalysis secured nearly €1m via the European Space Agency (ESA) to scale sustainable titanium production. Titanium is a critical metal for space and aerospace applications, and ESA is actively supporting the development of a more sustainable, economically viable, and secure production route. The two year project has both space and non-space applications, and builds on Metalysis’ proccess.
Metalysis websiteImages: Metalysis
The company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham it also operates a site at Manvers.
The current C-103 market is estimated at $46m, reaching $200m by 2032 as users search for alternative, secure and consistent supply of this high-performance refractory alloy for use within their high temperature and extreme environment applications.
The benefits of the Metalysis electrolysis process are that in contrast to traditional melting processes for metal alloy powder production, electrolysis uses much lower temperatures and less energy and is a single-stage process rather than multi-stage, such as titanium alloy production. Also, no hazardous chemicals are used during the Metalysis process. This gives substantial energy and yield savings and means that sustainability is built-in across the Metalysis production process.
Advertisement
The Metalysis process in contrast to melting is also highly adaptable, so bespoke materials can be produced as directed by specific customer demand.
C-103 alloy is one of the most widely used niobium alloys. Niobium’s melting point of 2477 degrees Celsius, excellent corrosion resistance and high strength to weight ratio ensures it is a metal of choice for critical sectors.
C-103 faces supply chain vulnerability primarily because of shortages in Hafnium metal (as opposed to hafnium oxide) production, as competing demand from other hafnium compounds has increased, driven by the rapid expansion of semiconductor chip manufacturing.
Demand is also set to increase also following recent advances in additive manufacturing (AM - 3D printing). The ability to manufacture complex C-103 structures and geometries with minimal material waste addresses one of the historical manufacturing challenges pertaining to C-103, reducing costs and lead times.
Nitesh Shah, CEO of Metalysis, said: "Metalysis is adding C-103 niobium hafnium titanium alloy to its product suite given our core focus on refractory alloys – combined with lightweighting expertise. C-103 was developed in the 1960s but now we are seeing a huge surge in demand because of the renewed race for space – as well as advanced manufacturing sectors such as hypersonics / defence.
"The Metalysis FFC process is able to produce C-103 alloy to the morphology required by AM partners – whilst reducing metal oxides rather than metal means we are not constrained by the availability of hafnium metal. Our engagement with customers in this sector has already been highly encouraging.”
In March Metalysis secured nearly €1m via the European Space Agency (ESA) to scale sustainable titanium production. Titanium is a critical metal for space and aerospace applications, and ESA is actively supporting the development of a more sustainable, economically viable, and secure production route. The two year project has both space and non-space applications, and builds on Metalysis’ proccess.
Metalysis websiteImages: Metalysis
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