Cornell Researchers Improve Metal Strength for 3D Printing

New Alloy Composition Method Enhances Additive Manufacturing for Stronger Parts

Researchers at Cornell University have developed a method to improve the strength and reliability of 3D printed metal parts. Their study, published in Nature Communications, explores how controlling the co

mposition of metal alloys during Additive Manufacturing (AM) can create stronger, more durable metal parts. This breakthrough has the potential to change the future of manufacturing industries.

Optimizing Metal Microstructure for Stronger Materials

Cornell’s research focuses on a common problem in AM: column-like grain structures that weaken metal parts. These structures typically form when metal solidifies too quickly. By adjusting the alloy’s manganese-to-iron ratio, the researchers were able to disrupt these column-like grains, resulting in a more uniform and stable grain structure. This change led to a significant increase in yield strength, making the material stronger overall.

“Grain size and phase stability are essential to material properties. By fine-tuning the composition, we can control the microstructure and enhance metal performance,” said Atieh Moridi, assistant professor of mechanical and aerospace engineering at Cornell University.

Groundbreaking Technology for Real-Time Data Collection

The researchers faced challenges in studying the rapid solidification process that occurs during AM. To overcome this, they utilized the Cornell High Energy Synchrotron Source, which allowed them to gather data in fractions of a second. This real-time data revealed an intermediate phase that disrupted column-like grain formation and refined the grain structure, boosting the metal’s performance.

“This method gives us a clearer understanding of how microstructural changes happen during the solidification process. It offers a solid foundation for producing stronger materials,” said Akane Wakai, Ph.D. candidate and lead author.

Broad Impact on Industries and Manufacturing

This discovery has far-reaching implications. It offers a way to produce 3D printed metal parts that are stronger, more reliable, and tailored for industries like aerospace, automotive, and electronics. With improved metal properties, manufacturers can reduce material waste, shorten production times, and design complex parts that are difficult or impossible to make with traditional methods.

“Additive manufacturing gives designers the freedom to innovate, which can lead to lighter parts and faster production. With stronger materials, we can unlock new possibilities for high-performance applications,” Wakai added.

The research, funded by the U.S. Department of Energy, National Science Foundation, and NASA, involved collaborations with NASA and the University of Pittsburgh.