Researchers at the US Department of Energy’s Oak Ridge National Laboratory developed DuAlumin-3D, a 3D printable aluminum alloy designed for high-temperature applications in aerospace and automotive components. The alloy, which contains cerium, nickel, and zirconium, went from concept to full-scale prototype automotive pistons in under three years—a process that traditionally takes 10 to 20 years.

DuAlumin-3D achieved a manufactured density above 99.9 percent and recorded the best-known creep resistance for a bulk aluminum alloy at 400°C. It also demonstrated strong fatigue resistance at 350°C. The alloy operates at temperatures approximately 150°C higher than conventional aluminum alloys, bringing it into range for applications previously reserved for titanium, steel, or nickel-based materials. At the same time, DuAlumin-3D weighs half as much as titanium and conducts heat nearly six times more efficiently.

In aviation, using DuAlumin-3D instead of titanium in heat exchangers could cut weight by hundreds of pounds per aircraft. Applied across commercial fleets, ORNL estimated this would save more than 50 million gallons of jet fuel annually, worth over $120 million. In automotive applications, replacing existing aluminum alloys with DuAlumin-3D could increase peak cylinder temperatures by 50–100°C and raise engine thermodynamic efficiency by up to 10 percent, with potential annual fuel savings of around $3 billion if adopted by 10 percent of the US automotive sector.

In 2025, General Motors used DuAlumin-3D in its Low Mass and High Efficiency Medium-Duty Truck Engine, a project that earned an R&D 100 award. The DOE’s Advanced Materials and Manufacturing Technologies and Vehicle Technologies Offices supported the research.