biostudies-literatureTakata NMEXT | Japan Society for the Promotion of Science (JSPS)MEXT | JST | Precursory Research for Embryonic Science and Technology (PRESTO)11105https://www.ebi.ac.uk/biostudies/studies/S-EPMC12705679biostudies-literatureUnknown16(1)Lightweight Al alloys with enhanced mechanical properties are essential for structural applications across various industries. To promote sustainable material flow, this study introduces an Al-Fe-based multi-elemental alloy series optimized for laser-based additive manufacturing (AM) using powder bed fusion (PBF-LB), leveraging recycling-friendly Al alloys with Fe as a major impurity. The alloy design is based on the concept of elemental partitioning into either the liquid phase (forming metastable Al₆Fe phase for strengthening) or the solid phase (α-Al matrix) during solidification. Investigations of PBF-LB processed Al-Fe-X ternary alloys (X: Cu, Mn, and Ti) reveal the distinct roles of these alloying elements: Cu and Mn stabilize the Al₆Fe phase, while Ti enhances Nature communicationsDesign of high-performance sustainable aluminum alloy series for laser additive manufacturing.PMC12705679JP22688912Suzuki AKim DKobashi MKato MMinamihama KWang WTakata NMiyawaki TCheng YXu YfalseDesign of high-performance sustainable aluminum alloy series for laser additive manufacturing.Lightweight Al alloys with enhanced mechanical properties are essential for structural applications across various industries. To promote sustainable material flow, this study introduces an Al-Fe-based multi-elemental alloy series optimized for laser-based additive manufacturing (AM) using powder bed fusion (PBF-LB), leveraging recycling-friendly Al alloys with Fe as a major impurity. The alloy design is based on the concept of elemental partitioning into either the liquid phase (forming metastable Al₆Fe phase for strengthening) or the solid phase (α-Al matrix) during solidification. Investigations of PBF-LB processed Al-Fe-X ternary alloys (X: Cu, Mn, and Ti) reveal the distinct roles of these alloying elements: Cu and Mn stabilize the Al₆Fe phase, while Ti enhances 2025-01-01T00:00:00Z2025 Dec2026-06-06T03:53:55.155Z2026-05-25T03:12:16.927ZS-EPMC127056794139796910.1038/s41467-025-67281-8