Metalysis, a producer of solid-state steel and alloy powders, is now producing high-purity aluminum scandium alloy (Al₃Sc) powder to fulfill rising demand from the semiconductor, aerospace, and protection sectors. The event comes as Western producers search safe, non-Chinese language sources of uncommon earth parts (REEs) and demanding minerals. Based mostly throughout two websites in South Yorkshire, UK, Metalysis is a strategically necessary midstream asset for the UK and its allies, aligning with the UK’s Important Minerals Technique: Imaginative and prescient 2035.
Metalysis at present produces a high-scandium aluminium alloy containing 36 wt% / 25 at% scandium (64 wt% / 75 at% aluminium) in totally homogenised kind. The fabric achieves oxygen ranges of 500 ppm and carbon ranges of fifty ppm, assembly the stringent purity necessities for semiconductor sputtering targets. It’s provided in powder kind or as consolidated discs.
The 36 wt% alloy is utilized in sputtering targets for thin-film deposition of aluminium scandium nitride (AlScN). AlScN allows next-generation bulk acoustic wave (BAW) filters and resonators with enhanced piezoelectric efficiency, supporting superior 5G and future networks, Wi-Fi enlargement, AI purposes, and the Web of Issues. Prospects can dilute the alloy with aluminum to provide decrease scandium loadings, enabling use as a grasp alloy for aerospace and protection purposes.
Not like typical melting routes, Metalysis makes use of its patented FFC Cambridge electrolysis course of to co-reduce aluminium oxide and scandium oxide straight in molten calcium chloride at 650–950°C. This solid-state course of consumes much less vitality, allows excessive scandium loadings, and delivers totally homogenised alloys with constant efficiency.
Metalysis operates 4 Gen 2 models, every able to producing as much as 350 kg of Al₃Sc yearly, addressing an estimated international market of three–4 tonnes per yr. Gen 3 models will allow tonne-scale output per unit, whereas Gen 4 models are designed for manufacturing on the tens-of-tonnes scale as demand grows.
“Metalysis has a transparent technique targeted on premium essential supplies. Our aluminium scandium alloy is totally homogenised and very low in impurities, making it superb for high-performance purposes in semiconductor manufacturing, while defence and aerospace producers are exploring purposes of decrease scandium loadings,” stated Nitesh Shah, CEO of Metalysis. “The latest REE export controls from China have accelerated pressing adoption of our aluminium scandium alloys, and we are actually scaling manufacturing to fulfill this demand, shifting from our Gen 2 models immediately to tonne-scale output from Gen 3 within the coming months.”
