Researchers at Tohoku University have developed a new approach to multi-material metal 3D printing, specifically addressing challenges in creating steel-aluminum components. The study focused on producing lightweight yet strong automobile parts using Laser Powder Bed Fusion (L-PBF) technology.
The research team tackled a common problem in metal 3D printing where combining materials like steel and aluminum typically results in brittle components. They discovered that increasing the laser scan speed during the printing process helps prevent the formation of weak intermetallic compounds at the interface between the two metals.
“Multi-materials are a hot topic in the field of additive manufacturing due to its process flexibility,” says Associate Professor Kenta Yamanaka from Tohoku University. “However, a major challenge in practical implementation is that for certain metal combinations, such as steel and aluminum, brittle intermetallic compounds can be formed at the dissimilar metal interfaces.”
The team successfully created a full-scale automotive suspension tower using their improved printing method. This demonstration shows the practical application of their research in producing functional automotive components that combine the strength of steel with the lightweight properties of aluminum.
The L-PBF process used in this study offers advantages over traditional manufacturing methods, including reduced material waste and the ability to create complex, customized shapes. The research team plans to extend their findings to other metal combinations, potentially expanding applications across various industries.
Source: eenewseurope.com