Researchers at Tohoku University in Japan have developed a new method for multi-material 3D printing that makes it possible to produce lightweight yet durable automotive components. The process combines different metals, such as steel and aluminium, and uses the precision of additive manufacturing to create complex and optimized components.
In metal printing, material is bonded together layer by layer using heat. This technology not only enables the production of individual geometries, but also reduces material waste compared to conventional manufacturing processes. Multi-material structures open up additional possibilities as they specifically combine different materials to improve the performance of a component. However, a major problem with such approaches is the formation of brittle intermetallic compounds at the interfaces between dissimilar metals, which can impair the mechanical properties.
To solve this problem, the researchers used Laser Powder Bed Fusion (L-PBF) technology, in which metal powder is selectively melted by a laser.
“Multi-materials are a hot topic in the field of additive manufacturing due to its process flexibility,” explains Associate Professor Kenta Yamanaka (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. So, while the material is now lighter, it ends up being more brittle.”
The result of this work was a fully functional prototype of an automotive component, a so-called strut brace, with customized geometry.
“In other words, you can’t just slap two metals together and expect them to stick without a plan,” says Specially Appointed Assistant Professor Seungkyun Yim (Tohoku University),”We had to fully understand the in-situ alloying mechanism first.”
The researchers plan to apply their findings to other metal combinations to further expand the possibilities of multi-material 3D printing. These developments could enable new applications in various industries, especially where weight and strength are crucial.
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