3D Printing
News Videos Newsletter Contact us
Home / News / MIT Researchers Strengthen Metal Prints with Induction Heating
qidi

MIT Researchers Strengthen Metal Prints with Induction Heating

November 21, 2022

Researchers from MIT have figured out a means of heat treating 3D printed metals so that they can be used in high temperature, high stress environments.

This means that one day it could be possible to 3D print superalloy turbine blades with similar mechanical properties and reliability as conventionally manufactured blades.

Microstructure

Traditionally, turbine blades and stator vanes are cast, and the molten metal is allowed to solidify in a lengthwise manner along the mold, resulting in larger, more robust grains that form in the direction of most stress.

It is preferable to use additive manufacturing for turbine blades for a variety of reasons including cost and environmental benefits. But until now, the printing process has resulted in parts that are susceptible to creep, which is exactly what you don’t want in a hot spinning metal part that requires mere microns of clearance at the end.

Turbine blades are very precise, and creep can result in the blade stretching and deforming under loads and heat. This creep is a result of the printed microstructure which can result in very fine grains measuring in the region of tens to hundreds of microns in length. In order to reduce the creep from such small grains, the grains must be produced.

Printed superalloy
Printed superalloy rod passing through a hot induction coil. (Image credit: MIT)

By heat treating printed metal parts with induction heating, the MIT researcher found that they were able to quickly melt and reform the grains into larger columnar grains aligned with the axis of greatest stress, which are more resistant to creep.

This extra heat treatment stage means that it is possible, in principle, to produce 3D printed superalloy turbine blades that retain their strength and dimensional stability to the point that they can function in the extreme environment of a gas turbine engine. Of course, the extra design freedom allowed by 3D printing means that new turbines and stator vanes with new geometries can be produced, which can potentially improve fuel consumption and energy efficiency.

“In the near future, we envision gas turbine manufacturers will print their blades and vanes at large-scale additive manufacturing plants, then post-process them using our heat treatment,” said Zachary Cordero, Professor of Aeronautics and Astronautics at MIT.

“3D-printing will enable new cooling architectures that can improve the thermal efficiency of a turbine, so that it produces the same amount of power while burning less fuel and ultimately emits less carbon dioxide.”

Induction Heating

By passing the printed metal through an induction coil at a particular speed, the researchers found that it resulted in the directional recrystallization of the small grains.

This method of heat treatment is almost a century old and has been used on wrought metals and alloys in the past.

By passing the nickel-superalloy parts at a speed of 2.5 millimeters per hour at a temperature of 1,235 C the team found they were able to maintain a thermal gradient in the part resulting in the melting of the fine grains and recrystallization in the direction of stress. After the part moves through the heated coil, it is passed directly into a bath of room temperature water for rapid cooling.

“The material starts as small grains with defects called ‘dislocations’, that are like a mangled spaghetti,” said Cordero. “When you heat this material up, those defects can annihilate and reconfigure, and the grains are able to grow. We’re continuously elongating the grains by consuming the defective material and smaller grains — a process termed recrystallization.”

The appearance of the columnar grains was confirmed by electron microscopy.

The next step is to move away from the rod-shaped metal pieces used in the experiments and move towards more turbine-blade shaped parts.

The research has been published in a paper titled “Directional recrystallization of an additively manufactured Ni-base superalloy” in the Additive Manufacturing journal.

You can access that paper over at this link.

steel
Related Story
X-Ray Research Yields Method for Printing Strongest Steel
Share:
WhatsApp Twitter Facebook LinkedIn Buffer Reddit E-mail
About the author | Phillip Keane
Phillip is an aerospace engineer from UK. He is a graduate of Coventry University (UK), International Space University (France) and Nanyang Technological University (Singapore), where he studied Advanced Manufacturing at the Singapore Centre for 3D Printing.
Join our newsletter

Our newsletter is free & you can unsubscribe any time.

Latest posts

Singapore Startup Creates Limited Edition 3D-Printed Collectibles from Recycled Plastic Bottles

Singapore-based startup Unigons has launched a limited collection of 3D-printed Merlion figurines made from recycled plastic bottles. The company produced 60 pieces of... read more »

News
Singapore Startup Creates Limited Edition 3D-Printed Collectibles from Recycled Plastic Bottles

Designer Uses Robotic 3D Printing to Create Dual-Purpose Dog Furniture

Designer Liam de la Bedoyere has developed the Dog Hut Side Table, a piece of furniture that combines a resting space for dogs... read more »

News
Designer Uses Robotic 3D Printing to Create Dual-Purpose Dog Furniture

Scientists 3D Print Solar-Powered Sponge for Seawater Desalination

Researchers have developed a 3D-printed aerogel material that uses sunlight to convert seawater into drinking water. The sponge-like structure contains microscopic vertical channels... read more »

News

Revopoint Launches Major Prime Event 2025 Sale with Up to 40% Off 3D Scanners and Accessories

Revopoint is kicking off its Prime Event 2025 with a series of major discounts on its range of professional 3D scanners and accessories.... read more »

News

Turkish Companies Test 3D Printed Component for Armored Vehicles

MetalWorm and Nurol Makina, both based in Ankara, Turkey, have completed testing of an armored vehicle component manufactured using Directed Energy Deposition (DED)... read more »

3D Printing Metal
Turkish Companies Test 3D Printed Component for Armored Vehicles

McGill Spinout Uses 3D Bioprinting to Create Tumors for Smarter Cancer Treatments

TissueTinker, a McGill University spinout company, has developed 3D bioprinting technology to create miniaturized tumor models for cancer drug testing. The company recently... read more »

Medical
McGill Spinout Uses 3D Bioprinting to Create Tumors for Smarter Cancer Treatments

University of Twente Awarded €13.6M for Research in Circular 3D Printing and Transparent AI

The University of Twente has received €13.6 million in funding from the 2024 NWA ORC program to lead two research projects focused on... read more »

News
University of Twente Awarded €13.6M for Research in Circular 3D Printing and Transparent AI

China’s 3D Printed Micro Turbojet Engine Completes Maiden Flight

The Aero Engine Corporation of China (AECC) has successfully completed the first flight test of its 3D-printed micro turbojet engine in Inner Mongolia... read more »

Aerospace
China's 3D Printed Micro Turbojet Engine Completes Maiden Flight

Laser-Assisted Cold Spray Technology Enhances Material Deposition Process

Researchers at the University of Cambridge's Center for Industrial Photonics have developed a new additive manufacturing technique called laser-assisted cold spray (LACS). The... read more »

3D Printing Metal
Laser-Assisted Cold Spray Technology Enhances Material Deposition Process

Social

  • Facebook Facebook 3D Printing
  • Linkedin Linkedin 3D Printing
Join our newsletter

Our newsletter is free & you can unsubscribe any time.

Featured Industries

  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Fashion
  • Medical
  • Military
  • QIDI Tech X-Max 3

    • - Print size: 325 x 325 x 315 mm
    • - fully enclosed
    More details »
    $799.00 QIDI Store
    Buy Now
  • QIDI Plus4

    • - Print size: 305 x 305 x 280 mm
    • - print temperature of 370°C
    More details »
    $799.00 QIDI Store
    Buy Now
  • Snapmaker Artisan Premium 3-in-1

    • - Print size: 400 x 400 x 400 mm
    • - comes with enclosure
    More details »
    $2,999.00 Snapmaker
    Buy Now
  • QIDI Tech Q1 Pro

    • - Print size: 245 x 245 x 245 mm
    • - 600mm/s max speed
    More details »
    $449.00 QIDI Store
    Buy Now

Company Information

  • What is 3D Printing?
  • Contact us
  • Join our mailing list
  • Advertise with us
  • Media Kit
  • Nederland 3D Printing

Blog

  • Latest News
  • Use Cases
  • Reviews
  • 3D Printers
  • 3D Printing Metal

Featured Reviews

  • Anycubic Photon Mono M5s
  • Creality Ender 5 S1
  • The Mole 3D Scanner
  • Flashforge Creator 3 Pro

Featured Industries

  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Medical
  • Military
  • Fashion
  • Art
2025 — Strikwerda en Dehue
  • Home
  • Join our mailing list
  • Contact us
Blog
  • Latest News
  • Use Cases
  • Reviews
  • 3D Printers
  • 3D Printing Metal
Featured Industries
  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Medical
  • Military
  • Fashion
  • Art
Company Information
  • What is 3D Printing?
  • Contact us
  • Join our mailing list
  • Advertise with us
  • Media Kit
  • Nederland 3D Printing