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Novel metal alloy withstands extreme conditions -- sets new benchmarks

A new high-temperature-resistant material exhibits great potential for applications such as energy-efficient aircraft turbines.

A new material developed by researchers at Karlsruhe Institute of Technology (KIT) in Germany may contribute to a reduction of the fossil fuels consumed by aircraft engines and gas turbines in the future.

The team has created a refractory metal-based alloy with properties unparalleled to date. The novel combination of chromium, molybdenum, and silicon is ductile at ambient temperature. With its melting temperature of about 2,000 C, it remains stable even at high temperatures and is, at the same time, oxidation resistant. The results are published in the journal Nature.

Alloy production by means of arc melting in the material synthesis lab of the Institute for Applied Materials - Materials Science and Engineering. [Credit: Photo by Chiara Bellamoli, KIT/Courtesy of KIT]

 

 

 

 

High-temperature-resistant metallic materials are required for aircraft engines, gas turbines, X-ray units, and many other technical applications. Refractory metals such as tungsten, molybdenum, and chromium, whose melting points are around or higher than 2,000 C, can be most resistant to high temperatures. Their practical applications, however, have limitations: They are brittle at room temperature and, in contact with oxygen, they start to oxidize, which can cause failure within a short time even at temperatures of 600 to 700 C. Therefore, they can only be used under technically complex vacuum conditions -- for example, as X-ray rotating anodes.

Due to these challenges, superalloys based on nickel have been used for decades in components that are exposed to air or combustion gases at high temperatures. They are used, for example, as standard materials for gas turbines.

"The existing superalloys are made of many different metallic elements including rarely available ones, so that they combine several properties. They are ductile at room temperature, stable at high temperatures, and resistant to oxidation," explains Professor Martin Heilmaier from KIT's Institute for Applied Materials - Materials Science and Engineering. "However, and there is the rub, the operating temperatures, i.e. the temperatures in which they can be used safely, are in the range up to 1,100 degrees Celsius maximum. This is too low to exploit the full potential for more efficiency in turbines or other high-temperature applications. The fact is that the efficiency in combustion processes increases with temperature."

A chance for a technological leap
This limitation was the starting point for Heilmaier's working group. Their work succeeded in developing a new alloy made of chromium, molybdenum, and silicon. This refractory metal-based alloy features hitherto unparalleled properties. "It is ductile at room temperature, its melting point is as high as about 2,000 degrees Celsius, and, unlike refractory alloys known to date, it oxidizes only slowly, even in the critical temperature range," says Dr. Alexander Kauffmann, a team development member who is now a professor at the Ruhr University Bochum. "This nurtures the vision of being able to make components suitable for operating temperatures substantially higher than 1,100 degrees Celsius. Thus, the result of our research has the potential to enable a real technological leap."

These characteristics are of marked importance, as resistance to oxidation and ductility still cannot be predicted sufficiently in materials development overall to allow for targeted designs -- despite the great progress that has been achieved in computer-assisted materials development.

"In a turbine, even a temperature increase of just 100 degrees Celsius can reduce fuel consumption by about five percent," says Heilmaier. This is particularly relevant to aviation. Stationary gas turbines in power plants could also be operated with lower CO₂ emissions thanks to more robust materials.

"In order to be able to use the alloy on an industrial level, many other development steps are necessary," says Heilmaier. "However, with our discovery in fundamental research, we have reached an important milestone. Research groups all over the world can now build on this achievement."

Source: Karlsruhe Institute of Technology

Published November 2025

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