RSP Technology

RSP Technology develops, produces and sells aluminum alloys with remarkable properties, though the use of the Rapid Solidification Processing (RSP) method. As a result of ultra fast cooling (converting more than 1 million degrees per second) a new super strong material with a very fine crystalline structure emerges. Through this production process we produce aluminum as strong as titanium, other alloys surpass the best conventional aluminium alloys by a factor 2 or even better. The RSP production method is the foundation for unique and superior materials, which offer new possibilities for lightweight high-end applications in medical, optical, racing- and space industries. The so called Rapid Solidification Processing (RSP) offers a large alloy freedom and gives the material a unique feature. The short production cycle makes RSP Technology a partner for material production and alloy development. During the meltspinning process, molten aluminum (800C) hits a fast rotating copper wheel and almost instantaneously releases a continuous metal ribbon at room temperature (20C). This ribbon is converted into flakes and finally into an extrusion product. Because of this process the material gets a high homogeneous compound and thereby forming a favorable microstructure. The name Rapid Solidification Process stems from the sudden temperature drop that takes place at a rate of more than 1,000,000 C per second as the aluminium comes in contact with the wheel. The ribbon is cut into small pieces and turned into a process able product through a few production steps. Depending on the desired alloy, a special heat treatment may be applied.

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RSP Microstructure
Aluminum as strong as titanium. Thanks to the extremely fast solidification of the meltspinning process, is the crystalline structure in the material very small ( 2 micron). Intermetallic compounds en and insoluble components are distributed fine en homogeneous over the metal matrix, thereby forming a favorable microstructure. These factors contribute to the higher strength of RSP alloys. The two pictures show the difference in microstructure between a RSP alloy and a conventionally cast aluminum alloy with an identical chemical composition.

left: RSP microstructure, right: conventional microstructure

Material specifications
The major advantages of RSP materials compared with conventional aluminum alloys: Higher strength Some RSP alloys can measure up to titanium in strength and offer an alternative for titanium that is heavier, more expensive and harder to work on. The RSA-708 alloy is often used for components in the sport and race industry. Higher stiffness RSP has a very high relative stiffness. Its stiffness is for example greater than that of steel. So its usable in a lot industrial markets. The reason of that is because the aluminium is resistant against high temperatures. That makes that the material is very suitable for turbine and engine parts. Lower expansion cofficient The expansion coefficient can be adapted by changing the composition of an alloy. Thus the RSP material is suitable for components of measure sensitive equipment (measuring instruments), deployed in changing temperature conditions. Also for use in pistons, a lower expansion coefficient is important; fewer margins lead to lower environmental Greater wear resistance Because of the high wear resistance of RSP alloys, surface treatments such as hard anodizing may be omitted under certain conditions. Lower weight Application of special alloys heightens the material strength, which makes the production possible of thinnerwalled (and therefore lighter) components. There are also RSP alloys with lower specific gravity. This allows a component to become lighter without having to change the design concept. Better temperature strength RSP alloys offer higher strength at elevated temperature applications. The alloys can be used for pistons, turbo components and components in systems that are subjected to temperature stress. The finely distributed silicium provides extra dispersion hardening.

pollution. Fine structure Higher hardness Higher hardness results in less wear of components, examples are hydraulic applications, pistons for race cars and diesel engines. Higher ductility The RSP materials produced by RSP Technology have, due to their unique microstructure, better material and tooling properties compared to other aluminum alloys. Production of different Aluminium alloys An enlargement van de solid solubility of the alloying elements leads to extra strength. Through precipitation treatments and/or dissolving hardening offers possibilities for the production of alloys that can not be achieved in a conventional manner, such as AlSi40 and AlSi50. RSP alloys have an extremely low surface roughness of only 2 nm. Very smooth surfaces make it possible to apply RSP aluminium in mirrors. Further the material can be used as mold material for synthetic precision components (lenses).