Metalysis begins commercial production of AI3Sc alloy powder
Metalysis, an end-to-end manufacturer of solid-state metal and alloy powders and an expert in materials science, is producing high-purity aluminium scandium alloy powder (Al₃Sc) to meet the critical requirements of the aerospace, semiconductor, and defence sectors as Western manufacturers seek non-Chinese sources of REEs and critical minerals
Metalysis produces a high-scandium-loaded aluminium scandium alloy, currently achieving 36% weight/25% atomic scandium (64% weight/75% atomic aluminium) in fully homogenised form, with oxygen levels at 500ppm and carbon at 50ppm.
This ultra-low impurity content ensures sputtering targets meet semiconductor manufacturing quality demands and is available in powder or consolidated disc formats.
The alloy at 36% weight and 25% atomic scandium is in high demand from international manufacturers of sputtering targets, which are used in thin film deposition to apply aluminium scandium nitride (AIScN) coatings to semiconductor components.
AIScN provides next-generation bulk acoustic wave (BAW) filters and resonators with enhanced piezoelectric properties, critical for advanced 5G and higher network rollout, WiFi expansion, AI applications, and the Internet of Things.
Customers can dilute the aluminium scandium alloy with aluminium to produce a lower scandium loading. This master alloy can be used in aerospace and defence applications.
On August 5 2025, Dr Vic Ramdass, acting assistant secretary of defence 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.”
Unlike traditional melting processes, which require scandium metal and struggle to achieve uniform homogenisation, Metalysis uses its patented FFC Cambridge electrolysis process to co-reduce scandium oxide and aluminium oxide feedstocks in molten calcium chloride electrolyte at 650–950°C. This process uses less energy, enables high scandium loadings, and provides a fully homogenised alloy with consistent performance.
Recent Chinese government export controls on rare earth elements, including scandium, and ongoing instability have accelerated Western supply chain diversification. Metalysis sources scandium oxide from several global suppliers to ensure a secure feedstock supply.
Gen 2 units serve as development units and have doubled in number at Metalysis to four. At capacity, each can produce up to 350kg of AI3Sc annually, while the market for aluminium scandium is 3-4 tonnes a year.
Through its various Gen units, Metalysis is positioned to meet this demand. The larger Gen 3 units will produce tonnes per year per unit. The company’s largest Gen 4 units can produce tens of tonnes annually, meeting demand as it grows.
Metalysis recently completed Spark Plasma Sintering (SPS) and hot pressing of its 36% weight aluminium scandium powder with RHP-Technology to produce discs that demonstrate the material’s physical and chemical properties.
Chemical composition was uniform throughout the disc, and relative densities exceeding 98% were achieved. SPS trials also achieved 10% weight scandium loadings through dilution with aluminium powder.
Nitesh Shah, Metalysis CEO, 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, whilst defence and aerospace manufacturers are exploring applications of lower scandium loadings. 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.”