G LI, Yuhe Huang, Chunlu Zhao, Xi He, Shuo Wang, Qiyang Tan, Y Li, Fucong Lyu, Guanghui Feng, Junhua Luan, Wanqian Hu, Zhenmin Li, Xinggang Li, Yanjin Xu, Yuansong Zeng, Zhiqiang Li, Xinping Mao, Ming‐Xing Zhang, Lehua Qi, Qiang Zhu, Jian Lu
Aluminum (Al) alloys are pivotal structural materials, indispensable for advanced energy-saving solutions and lightweight technologies. However, the limited heat resistance and low critical strength of the present commercial Al alloys at elevated temperatures (300-400 °C) have constrained their broader applications. Here, we present a facile strategy to additively manufacture strong yet ductile heat-resistant Al alloys using laser powder bed fusion (PBF-LB). By embedding heat-resistant multicomponent intermetallic nanophases (HMINPs) at the solidified cell boundaries, the as-printed alloy forms thermally stable cellular structures containing a high-volume fraction (~14 vol%) of HMINPs. Without any additional post-treatment, our as-printed Al alloy exhibits an average room-temperature tensile strength of 582 MPa, combined with a tensile strength of 114 MPa and exceptional creep resistance at 400 °C. The partial solid-state amorphization of the HMINPs during tensile straining at 300-400 °C creates a nano-dual-phase glass-crystal structure, providing an additional toughening mechanism. This HMINP strategy and PBF-LB's freeform manufacturing capability enable large-scale industrial use of our high-performance Al alloy, holding great promise for advancing energy efficiency, carbon neutrality, and sustainable manufacturing.