Metalysis begins production of Al₃Sc alloy powder

Metalysis has started commercial production of high-purity aluminium scandium alloy powder (Al₃Sc), responding to rising global demand triggered by Chinese export controls on rare earth elements. The alloy is aimed at critical applications in the semiconductor, aerospace and defence sectors as Western manufacturers seek secure, non-Chinese sources of REEs and critical minerals.

The South Yorkshire-based company operates across two sites and is regarded as a key midstream asset for the UK and its allies. The UK’s Critical Minerals Strategy: Vision 2035, published last month, commits to building out midstream processing as a strategic imperative.

Metalysis currently produces a high scandium-loaded aluminium scandium alloy, achieving 36 weight % scandium (25 atomic %) and 64 weight % aluminium (75 atomic %) in fully homogenised form. Oxygen levels are just 500ppm and carbon 50ppm, ensuring sputtering targets meet the strict quality demands of semiconductor manufacturing. The material is available in powder or consolidated disc formats.

This alloy is in high demand from international manufacturers of sputtering targets used in thin-film deposition to apply aluminium scandium nitride (AlScN) coatings to semiconductor components. AlScN enables next-generation bulk acoustic wave (BAW) filters and resonators with superior piezoelectric properties, essential for advanced 5G roll-out, Wi-Fi expansion, AI applications and the Internet of Things.

Customers can dilute the alloy with aluminium to produce lower scandium loadings for aerospace and defence applications. Dr Vic Ramdass, acting assistant secretary of Defense for Industrial Base Policy, said: “Scandium alloys are increasingly replacing titanium and legacy aluminium alloy components in DoD systems due to their superior lightweight, high-strength characteristics.”

Delivers a fully homogenised alloy
Unlike traditional melting processes, which require costly scandium metal and face challenges in achieving uniform homogenisation, Metalysis uses its patented FFC Cambridge electrolysis process to co-reduce scandium oxide and aluminium oxide feedstocks in molten calcium chloride at 650-950°C. This solid-state process consumes less energy, enables market-making scandium loadings and delivers a fully homogenised alloy with consistent performance characteristics.

Metalysis sources scandium oxide from multiple global suppliers, ensuring a secure and diversified feedstock supply. Recent Chinese government export controls on rare earth elements, including scandium, have accelerated Western supply chain diversification.

The company’s Gen 2 units have recently doubled to four, each capable of producing up to 350kg of Al₃Sc annually. The market for aluminium scandium is estimated at 3 to 4 tonnes a year. Larger Gen 3 units will enable output of tonnes per year per unit, while Gen 4 units can produce tens of tonnes annually to meet growing demand.

Metalysis recently completed Spark Plasma Sintering (SPS) and hot pressing of its 36wt% aluminium scandium powder in partnership with RHP-Technology GmbH, producing discs that demonstrated uniform chemical composition and relative densities exceeding 98%. SPS trials also achieved 10wt% scandium loadings via dilution with aluminium powder, demonstrating versatility to produce an array of scandium-containing aluminium alloys.

Metalysis CEO Nitesh Shah said: “Metalysis has a clear strategy focused on premium critical materials. Our aluminium scandium alloy is fully homogenised and extremely low in impurities, making it ideal for high-performance applications in semiconductor manufacturing, while defence and aerospace manufacturers are exploring applications of lower scandium loadings.

He concluded: “The recent REE export controls from China have accelerated urgent adoption of our aluminium scandium alloys, and we are now scaling production to meet this demand, moving from our Gen 2 units today to tonne-scale output from Gen 3 in the coming months.”