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The science and technology of light metals is relatively new – but it has had a transformative effect that can be seen across virtually every aspect of product manufacture and performance. It is an ongoing revolution that is still accelerating in its pace of change and expansion of accessibility.
In the realm of engineered products, light metals and their derivatives play perhaps the most pivotal role in delivering the balance between strength, durability, cost and weight reduction. From aerospace to automotive, from medical to consumer products, this wide and growing class of materials delivers durability/performance, fuel efficiency, and sustainability.
Pure elemental metals like Magnesium, Titanium, and Beryllium offer exceptional strength-to-weight ratios, varied levels of elevated corrosion resistance, and great versatility, making them ideal for high-performance applications. While pure Aluminum is of limited applicability due to its softness, once alloyed it represents the widest-use family of light metals. The capability and utility of light metals is greatly expanded through alloying, and through metal matrix composites (MMCs), foamed metals, and internally structured metal derivatives, which deliver greatly improved mechanical properties and can also aid in thermal stability, and manufacturability.
With the accelerating pace of development in additive manufacturing, nano-materials, and material science in general, light metals are being engineered into lattice structures, foams, and reinforced composites that aggressively push the boundaries of what’s possible.
This blog explores the various types and classes of light metals and alloys and their derivatives, their unique properties.
Sean B.
Mechanical Engineer
"I've recommended it to all my colleagues in manufacturing."
Jiga is the best way to get the parts you need, when you need them.
Elemental Light Metals and Salts
These metals can be used in the atomically pure state, but they’re more commonly used as constituents in alloys, where they are either the major matrix component or minority component, modifier additions. The exception to this is Titanium, which is often used in its pure state. The light elemental metals belong in 3 groups in the periodic table;
- Group 1 – Alkali Metals
Lithium (Li). This is widely used as a battery metal, in its chemically pure state and in various salts for catalytic purposes. It is of no use in structural applications when pure, but the pure form is extensively used across roles that benefit from its reactive nature.
- Group 2 – Alkaline Earth Metal
Magnesium (Mg). This is used in the pure state for certain high value applications, where weight is a critical factor. It is more commonly alloyed, as both a major constituent for weight, or a minor constituent for its influence on properties.
Beryllium (Be) is used in its pure state for high temperature lightweight parts in optical, military and space applications, where its low density and high rigidity/thermal stability are beneficial. It is much more commonly used as a minority component in alloys, for its influence on mechanical and thermal properties.
- Group 4 and Group 14 – Transition Metals
Titanium (Ti, Group 4(IVb)) is also relatively widely used in the pure form, for very high strength combined with extreme corrosion resistance.
Aluminum (Al, Group 13) is used in its pure form for high thermal and electrical conduction applications such as heat guides and high tension electrical cables.
Here’s a clear, concise table outlining processing methods for light metals, metal foams, and metal/composite materials that you can add to your blog or resource document:
Light Metal Alloys
Metal Matrix Composites (MMCs)
- Aluminum Matrix Composites (Al-MMCs) – Reinforced with silicon carbide (SiC) or carbon fibers for higher strength, stiffness, and wear resistance.
- Magnesium Matrix Composites (Mg-MMCs) – Reinforced with Boron carbide whiskers or Carbon nanotubes, used in aerospace and high-value, lightweight structural applications.
- Titanium Matrix Composites (Ti-MMCs) – Strengthened with ceramic whiskers or fibers for extreme strength/rigidity in aerospace and defense applications.
Foamed and Cellular Metals (High strength with reduced weight)
Foamed metals are at the leading edge of research and development in light metals, delivering considerably reduced weight (<50%) and various surprising mechanical and thermal benefits.
- Aluminum Foam – Open- or closed-cell structure, offering high energy absorption and impact resistance, used in automotive and structural damping applications.
- Titanium Foam – High strength, lightweight, and biocompatible, used in medical implants and aerospace.
- Nickel Foam – Highly conductive and corrosion-resistant, used in battery electrodes and filtration systems.
Lattice and Internally Structured Metal Derivatives
The most interesting and research intensive area in light metal technologies lies in methods for creating beneficial structures in the ‘construction’ of parts that remove material to reduce weight, while aiming to maintain and even improve mechanical, thermal and chemical properties selectively.
- Gyroid-Structured Titanium/Aluminum – Gyroid-structured Titanium and Aluminum represent a cutting-edge advancement in lightweight, high-strength materials. The gyroid lattice is a mathematically derived, self-supporting structure of interconnected tube walls that provides exceptional strength-to-weight ratios, enhanced energy absorption, and superior mechanical performance. They are defined by being continuous, triply periodic minimal surfaces (TPMS).
In aerospace and automotive engineering, gyroid-structured titanium is utilized in lightweight structural components, heat exchangers, and impact-resistant materials, optimizing various vehicle fuel efficiency without compromising strength and crash endurance.One key advantage of gyroid structures is their high surface area and tunable porosity, making them ideal for biomedical implants, particularly in bone scaffolds and prosthetics, where osseointegration (bone growth into the structure) is essential.
Additive manufacturing (3D printing) has made these complex geometries feasible, allowing for customized, lightweight, and highly durable components.
- Hollow Metallic Microlattices – Hollow metallic microlattices are a class of architected materials designed for extreme weight reduction while maintaining structural integrity. These materials consist of thin-walled, interconnected tubular struts arranged in a lattice pattern, allowing for exceptional strength-to-weight ratios, energy absorption, and mechanical resilience.
One of the lightest known metallic structures, hollow microlattices can have densities as low as 0.01 g/cm³, making them ideal for aerospace, automotive, and defense applications where weight savings are critical. Their unique architecture also provides superior shock absorption and impact resistance, making them valuable in protective gear, lightweight armor, and crash-resistant structures.
Hollow microlattices also have promising applications in thermal management and energy storage, as their high surface area enhances heat dissipation in battery electrodes and heat exchangers. They are typically fabricated using template-assisted deposition or advanced additive manufacturing techniques, enabling precise control over geometry and wall thickness.
Compared to solid metal foams or traditional lattices, hollow metallic microlattices offer a higher stiffness-to-weight ratio, improved energy efficiency, and superior mechanical performance.
These material forms focus on minimizing material usage through tubular struts, unlike gyroid structures. They exploit complex, smooth surfaces for multifunctionality. Additionally, microlattices are often fabricated via hollow tube deposition, whereas gyroids are commonly 3D-printed.
- Porous Metal Structures (e.g., Raney Nickel) – Porous metal structures are materials with a highly interconnected network of typically random voids, offering high surface area, lightweight properties, and excellent permeability.
They are engineered using powder sintering, foaming, and dealloying, where an alloying agent is chemically removed to leave the desired matrix. These techniques allow precise control over porosity and mechanical properties. Their high surface area enhances catalytic reactions, filtration efficiency, and heat dissipation – invaluable in chemical processing, energy storage/batteries, biomedical implants, and some aerospace applications.
In comparison with solid metals, porous metals offer considerable weight reduction, improved thermal regulation, and fluid transport properties.
- Composite metal foams (CMFs) – These are advanced materials that combine metallic matrices with gas-filled pores, offering an excellent strength-to-weight ratio. They can be formed either by direct gasification, or more commonly by the compositing of molten metal with gas filled microspheres.
Typically made from Aluminum, Steel, or Titanium, CMFs deliver exceptional energy absorption, thermal insulation, and impact resistance. These foams are used in aerospace, automotive, and military applications for lightweight armor, crash protection, and fire-resistant barriers.
Unlike solid metals, CMFs dissipate energy effectively, reducing impact forces and improving structural efficiency. Their ability to withstand extreme temperatures and resist radiation makes them valuable in nuclear and space applications. CMFs continue to evolve, offering new possibilities in engineering and high-performance manufacturing.
Light metal selection
Do you need the lightest possible structure?
YES: Choose Hollow Metallic Microlattices (ultralight, excellent strength-to-weight)
NO: Continue to strength evaluation
Is a high strength-to-weight ratio critical?
YES: Consider Titanium or Beryllium alloys, or Gyroid-Structured Metals (high performance, strong, efficient material distribution)
NO: Continue to corrosion resistance evaluation
Is corrosion resistance a priority?
YES: Choose Titanium, Aluminum, or Raney Nickel depending on exposure conditions (Raney Nickel for catalytic applications, Aluminum for moderate conditions, Titanium alloys for aggressive conditions)
NO: Consider Magnesium alloys (coated for improved chemical resistance) or Composite Metal Foams (CMFs can offer tunable corrosion properties)
Is cost a major concern?
YES: Choose Aluminum alloys (affordable & corrosion-resistant)
NO: Consider Gyroid-Structured Metals or CMFs for performance
Does the material need to withstand high temperatures?
YES: Choose Titanium or Beryllium alloys, or Composite Metal Foams
NO: Consider Aluminum or Magnesium alloys
Is electrical or thermal conductivity important?
YES: Choose Aluminum or Beryllium alloys, or **Raney Nickel**
NO: Consider Titanium or Gyroid-Structured Metals
Is shock absorption or impact resistance needed?
YES: Choose Composite Metal Foams (absorbs energy efficiently)
NO: Consider Titanium for structural applications
Is machinability or formability crucial?
YES: Choose Aluminum or Magnesium alloys, or Hollow Microlattices
NO: Choose Titanium alloys, Gyroid Structures, or CMFs for strength
Javier L
Principal Systems R&D Mechanical Engineer
"Game changing in the online manufacturing space"
Jiga is the best way to get the parts you need, when you need them.
Conclusion
Light metals became key in many markets, first entering widespread service during the Second World War, moving quickly from military applications to the universal, preferred solution in many engineering applications.
While alloying techniques and constituents are continuing to develop, the new frontier in light materials is the imposition of micro and macro structures that lift performance, or improve weight reduction or enhance specific chemical, electrical or mechanical performance criteria. This development area is closely bound with additive manufacturing, and is liable to dramatic expansion in demand as 3D printing methods improve and costs in processing decline.
