THE CHALLENGE
The key challenge in developing advanced lightweight materials for industries like aerospace, automotive, and energy lies in creating nanoporous metals that are both ultra-light and mechanically robust. While these materials offer exciting benefits such as low density, high surface area, and potentially superior strength, current manufacturing methods struggle to produce consistent, defect-free nanoscale structures. Issues like brittle fracture, crack initiation from tiny imperfections, and instability of the delicate nanoscale ligaments under stress or heat limit their practical use. This gap between promising lab-scale properties and real-world durability presents a significant business hurdle: without reliable, scalable production of tough, high-performance nanoporous metals, industries cannot fully capitalize on their potential to reduce weight and improve efficiency in critical structural and catalytic applications. Bridging this divide could unlock new markets and transform materials design across multiple high-value sectors.
OUR SOLUTION
We introduce a breakthrough class of lightweight materials called nanoporous high-entropy alloys (NHEAs), engineered by blending multiple metals and carefully removing a sacrificial element to create a finely controlled, nanoscale porous network. This innovative process produces materials that are significantly stronger and more durable—up to 5 to 10 times better—than traditional nanoporous metals, while maintaining low weight. By overcoming common issues like brittleness and instability, these alloys offer a uniquely stable and tough structure ideal for critical industries such as aerospace, automotive, defense, and nuclear energy. This technology not only enhances performance but also opens new opportunities for manufacturers seeking materials that combine strength, lightness, and reliability, ultimately driving greater efficiency and safety in high-demand applications.
Figure: The red box represents the nanoporous HEA Al0.1CoCrFeNi and the blue box represents the nanoporous HEA NbMoTaW, highlighting their distinctive values in specific strength and specific modulus.
Advantages:
- 5–10× higher specific strength than single-element nanoporous metals
- Enhanced toughness and reduced brittleness with improved strain hardening
- Superior thermal stability up to 1273 K
- Scalable fabrication compatible with additive manufacturing and liquid-metal dealloying
Potential Application:
- Lightweight aerospace and automotive structural components
- Ballistic armor and defense vehicle panels
- Radiation-tolerant nuclear reactor materials
- High-performance catalysts and energy storage electrodes
