The American Hughes Research Laboratory (HRL) has developed high-strength aluminum alloy (including Al7075 and Al6061) additive manufacturing technology, which lays the foundation for the alloying of other engineering structures, especially high-strength alloys such as high-strength steel and nickel-based superalloy. Important basis. Metal additive manufacturing typically employs an alloy powder that is heated by a laser or other direct heat source to melt and solidify the powder layer. However, most of the current metal materials cannot be manufactured by 3D printing. If high-strength non-weldable aluminum alloys such as Al7075 or AL6061 are used directly, the resulting parts will cause severe thermal cracking. To this end, the research team's first goal was to figure out how to completely eliminate hot cracks. The researchers tried to control the microstructure and focused on the way the material solidified. Based on nucleation theory, HRL solves this problem by using nanoparticle functionalization technology. The specially selected zirconium-based nanoparticles are added to the high-strength non-weld alloy powder to realize the nanoparticle functionalization of the alloy powder, which is then added to the additive manufacturing equipment, and is melted layer by layer by laser to construct a three-dimensional object. During melting and solidification, the nanoparticles become nucleation sites for the desired alloy microstructure, preventing hot cracks and maintaining high alloy strength in the fabricated parts. Since the melting and solidification in additive manufacturing is similar to welding, the nanoparticle functionalization technology developed by HRL can also be used to solve the welding problem of non-weldable alloys. This technique also enables the use of low cost materials such as conventional alloy powders and nanoparticles, which are uniformly distributed on the surface of the metal powder particles. In addition, during the research process, in order to find the right nanoparticles, the HRL research team used the CitrineInformatics data analysis platform in the United States to help find particles with the required characteristics through a large amount of public material database. The technology was developed by Hunter Martin and Brennan Yahata of HRL's Sensor and Materials Laboratory, and a paper on high-strength aluminum alloy additive manufacturing was published in the September 21, 2017 issue of Nature.
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