Elaboration and analysis of patent indicators on powder production and aluminum alloys used in additive manufacturing

Aluminum (Al) alloys for Additive Manufacturing (AM) involve several challenges, including high reflectivity, susceptibility to solidification cracking, and defect formation. These limitations have been progressively addressed through the development of new alloy compositions and advances in powder production technologies. In the present work, patent indicators focused on powder production and the development of aluminum alloys for AM were analyzed with the objective of mapping the state of the art, technological trends, and strategic actors using the Derwent Innovations Index (DII) database and Natural Language Processing (NLP) tools such as VantagePoint software. The research highlights that, while conventional aluminum alloys such as the 6 xx and 7xx series are susceptible to solidification cracking, there has been growing interest in modified alloy compositions specifically designed for AM, typically containing Ti, Zr, and Sc additions to reduce cracking and defect formation during printing. Traditional powder production methods, particularly gas atomization, continue to dominate commercially due to their high productivity and low cost. At the same time, alternative techniques such as ultrasonic and centrifugal atomization remain relevant because of their ability to produce powders with superior morphological quality and fewer defects. China has emerged as the leading country in patent filings, with state universities driving the development of new aluminum alloys, while companies primarily focus on gas atomization technologies. Consequently, this work may support strategic Research and Development (R&D) decisions, enabling the identification of innovation gaps and the monitoring of global competition.