New Titanium Alloy Created with 3D Printing Technology

An international research team, including members from Australia's RMIT University and the University of Sydney, has combined alloying and 3D printing techniques to create a new type of titanium alloy. This alloy exhibits strength under tensile stress without becoming brittle. Published in the latest issue of "Nature," this breakthrough offers hope for developing a new class of more sustainable high-performance titanium alloys for applications in aerospace, biomedical, chemical engineering, space, and energy technologies.

The new titanium alloy consists of a mixture of two types of titanium crystals, known as the α-phase and β-phase, each corresponding to a specific atomic arrangement. Oxygen and iron are the two most powerful stabilizers and strengtheners for the α-titanium phase and β-titanium phase, respectively. These elements are abundant and inexpensive.

However, researchers identified two challenges that hinder the development of tough α-β titanium-iron alloys through traditional manufacturing processes:

1. Oxygen can make titanium brittle.
2. Adding iron may lead to severe metallurgical defects, forming large β-titanium chunks.

The team employed laser-directed energy deposition to print their alloy from metal powder, a 3D printing technique suitable for creating large, complex parts. By integrating alloy design concepts with 3D printing process design, they identified a series of alloys that are strong, ductile, and easy to print.

The critical factor driving this success is the unique distribution of oxygen and iron atoms within and between the α-titanium and β-titanium phases. Researchers designed a nanoscale oxygen gradient within the α-titanium phase, featuring a high-oxygen segment for strength and a low-oxygen segment for ductility. This controlled the local atomic bonds and reduced the potential for brittleness.

The team noted that the performance of these new alloys is comparable to commercial alloys.

Professor Simon Ringer, Deputy Vice-Chancellor at the University of Sydney, stated that this research introduces a new titanium alloy system with broad and adjustable mechanical properties, high manufacturability, significant emission reduction potential, and provides insights for designing similar system materials.

Researchers emphasized that their design incorporates circular economy principles, creating potential for using industrial waste and low-grade materials to produce new titanium alloys.

Additionally, oxygen embrittlement is a significant metallurgical challenge not only for titanium but also for other important metals like zirconium, niobium, molybdenum, and their alloys. This new research may offer a template for alleviating these oxygen embrittlement issues through 3D printing and microstructure design.

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