Amorphous metal 3D printing process: a new technology that breaks through traditional manufacturing

Amorphous metal 3D printing process is an additive manufacturing technology based on the principle of rapid solidification. In recent years, with the rapid development of 3D printing technology and the expansion of new materials such as amorphous metals, amorphous metal 3D printing process has gradually become an important way to manufacture high-performance metal parts. This article will explore in depth the principles, processes, technical challenges and applications of amorphous metal 3D printing process.

1.Overview of amorphous metals

Amorphous metals, also known as metallic glasses, are materials with unique atomic structures. Their atomic arrangement is not ordered like traditional crystals, but presents a disordered state. This special structure gives amorphous metals a series of excellent physical and chemical properties. First, amorphous metals have extremely high strength and hardness, often far exceeding traditional crystalline metals.

This makes them perform well when subjected to heavy loads and impacts, and are not easily deformed or damaged. Secondly, amorphous metals also have excellent wear resistance and corrosion resistance, and can maintain stable performance in harsh environments. In addition, amorphous metals also exhibit good soft magnetic properties and high elastic limit, which make them an ideal material choice in many high-tech fields.

2.Introduction to 3D printing technology

(1) Principles of 3D printing technology

3D printing, also known as additive manufacturing, is a rapid prototyping technology. This technology builds objects by stacking materials layer by layer. Its basic principle is to slice the three-dimensional model designed by the computer into multiple two-dimensional layers, and then use a special 3D printer to stack the materials (such as plastic, metal powder, etc.) layer by layer to finally form a solid object.

This process does not require traditional machining or molds, and can directly manufacture parts with complex shapes based on digital models, greatly improving manufacturing flexibility and efficiency.

(2) Development history of 3D printing technology

3D printing technology originated in the late 19th century and gradually matured in the 1980s. In 1986, Charles Hull invented SLA technology and launched the first commercial 3D printer. In 1990, SLS technology was developed by Carl Deckard and Joe Beaman. Since then, FDM, LOM and other technologies have emerged one after another. In 2005, ZCorp launched the first high-definition color 3D printer.

In 2010, 3D printing technology began to be applied to automobiles, aviation and other fields. In recent years, open source 3D printers and biomedical applications have promoted the popularization and democratization of technology. With the advancement of materials science and software algorithms, 3D printing is becoming an important trend in the manufacturing industry.

3.Principle of amorphous metal 3D printing process

The amorphous metal 3D printing process combines the characteristics of amorphous metals with the advantages of 3D printing technology. By precisely controlling the temperature and cooling rate during the printing process, it ensures that the material maintains an amorphous structure during the molding process. Specifically, during the printing process, the metal powder is rapidly heated to a molten state by a high energy source such as a laser or electron beam, and then rapidly cooled to form an amorphous thin layer.

These thin layers are stacked layer by layer to eventually form the desired complex structure. Since amorphous metals are prone to form a crystalline structure during the cooling process, controlling the cooling rate is the key to maintaining the amorphous state. The amorphous metal 3D printing process requires not only high-precision temperature control, but also a deep understanding of the material’s fluidity and consolidation behavior.

4.Amorphous metal 3D printing process operation flow

Amorphous metal 3D printing process is a cutting-edge technology that builds objects by adding materials layer by layer. The following is its detailed process flow:

(1) Preliminary preparation

1) Select 3D printing equipment:

Make sure to select a 3D printer suitable for amorphous metal printing, such as selective laser melting (SLM) or electron beam melting (EBM) equipment.

2) Material preparation:

Prepare amorphous metal powders, such as zirconium-based, titanium-based or iron-based amorphous alloy powders. These materials have excellent mechanical properties and corrosion resistance.

3) 3D modeling:

Use computer-aided design (CAD) software to create a 3D model of the required object. Ensure that the model design is reasonable and avoid complex suspended structures to reduce support requirements.

(2) Data preparation and slicing processing

1) Model conversion:

Convert the 3D model into a format that the printer can recognize, such as STL format.

2) Slicing:

Use slicing software (such as Cura, MakerBot, etc.) to slice the model into a series of thin slices (layers) and set printing parameters such as layer thickness, printing speed, filling density, etc. Amorphous metal printing usually requires a thinner layer thickness to ensure accuracy.

(3) Printing environment settings

1) Printing platform preparation:

Clean the printing platform and ensure its levelness. For some amorphous metals, it may be necessary to preheat the platform to reduce thermal stress.

2) Atmosphere control:

Amorphous metal printing needs to be carried out under the protection of inert gas, such as argon or nitrogen, to prevent metal powder from oxidizing at high temperatures.

(4) Printing process

1) Loading metal powder:

Load amorphous metal powder into the powder supply system of the printer.

2) Start printing:

Transfer the sliced ​​file to the 3D printer and start the printing program. The printer spreads and melts the powder layer by layer according to the slicing data. Each layer of powder is melted and bonded to the previous layer under the action of the laser or electron beam.

3) Real-time monitoring:

Observe the printing process through the printer monitoring interface to promptly detect and deal with abnormal situations, such as powder splashing, uneven melting, etc.

(5) Post-processing

1) Support removal:

After printing, carefully remove the support structure on the print to avoid damaging the print.

2) Heat treatment:

Amorphous metal prints usually require heat treatment to release stress and improve their mechanical properties. The heat treatment process must be carried out under vacuum or inert gas protection to prevent oxidation.

3) Surface treatment:

Surface treatment of the print, such as grinding and polishing, is performed on the print to improve its surface finish and dimensional accuracy.

4) Quality inspection:

Use 3D scanners, X-ray inspection and other means to inspect the quality of the print to ensure that it meets the design requirements.

5.Common amorphous metal 3D printing process materials

(1) Titanium-based amorphous alloys:

Titanium-based amorphous alloys have high strength, low density and excellent biocompatibility, and are very suitable for use in the medical field, such as manufacturing artificial joints and bone implants. Its amorphous structure is precisely controlled by 3D printing technology, giving the material excellent mechanical properties and high corrosion resistance.

(2) Zirconium-based amorphous alloys:

Zirconium-based amorphous alloys are known for their high hardness, wear resistance and impact resistance. Through the amorphous metal 3D printing process, zirconium-based amorphous alloys can be formed into complex geometric shapes, which are suitable for manufacturing high-performance sports equipment and aerospace components.

(3) Iron-based amorphous alloys:

Iron-based amorphous alloys have high magnetic permeability and low loss characteristics, making them widely used in the fields of electronics and sensors. Amorphous metal 3D printing process can produce components with precise magnetic properties, such as transformer cores and inductors.

(4) Copper-based amorphous alloys:

Copper-based amorphous alloys have good electrical and thermal conductivity and are suitable for manufacturing electronic packaging materials and thermal management components. Through the amorphous metal 3D printing process, the complex structure manufacturing of copper-based amorphous alloys can be achieved, improving the heat dissipation efficiency of electronic equipment.

(5) Nickel-based amorphous alloys:

Nickel-based amorphous alloys have excellent corrosion resistance and high-temperature strength, making them very suitable for the manufacture of chemical equipment and aerospace engine components. The amorphous metal 3D printing process can precisely control the microstructure of nickel-based amorphous alloys and further improve their performance.

6.Key technical challenges and solutions for amorphous metal 3D printing processes

Amorphous metal 3D printing processes have attracted much attention due to their unique advantages and broad application prospects, but they also face a series of technical challenges. The following are key technical challenges and their solutions:

(1) Thermal stress control

1) Challenge: Amorphous metals are prone to thermal stress during the cooling process, causing deformation or cracking of printed parts.

2) Solution: Use preheated substrates and gradient cooling technology to control the cooling rate and reduce thermal stress concentration. In addition, optimize the printing path and layer thickness to avoid local overheating.

(2) Improved printing accuracy

1) Challenge: The rapid solidification characteristics of amorphous metals make it difficult to control printing accuracy.

2) Solution: Use high-precision laser or electron beam melting technology, combined with a real-time feedback system, to accurately control the temperature and size of the molten pool to ensure printing accuracy.

(3) Material performance consistency

1) Challenge: Amorphous metals have complex compositions, and composition segregation is prone to occur during the preparation process, affecting performance consistency.

2) Solution: Optimize alloy composition design and use homogenization heat treatment process to improve material uniformity. At the same time, strictly control printing parameters to ensure consistent performance of each part.

(4) Porosity control

1) Challenge: Porosity is easily generated during 3D printing, affecting the mechanical properties and corrosion resistance of amorphous metals.

2) Solution: Reduce the formation of pores by optimizing printing parameters such as laser power, scanning speed and powder feeding amount. In addition, use post-processing processes such as hot isostatic pressing to further reduce porosity.

(5) Cost and efficiency

1) Challenge: Amorphous metal 3D printing equipment and materials are expensive, and printing efficiency is relatively low.

2) Solution: Develop low-cost and high-efficiency printing technologies, such as the combination of selective laser melting and arc additive manufacturing. At the same time, optimize the process flow, improve material utilization, and reduce production costs.

7.Application of amorphous metal 3D printing process

(1) Aerospace field

Amorphous metal 3D printing process is widely used in the aerospace field. Due to its high strength, low weight and excellent fatigue resistance, amorphous metals are very suitable for manufacturing complex parts of aircraft and rockets. For example, 3D printing technology can be used to manufacture lightweight engine parts, fuel nozzles, etc., effectively reducing fuel consumption and improving aircraft performance.

(2) Medical field

The biocompatibility of amorphous metals makes it have great potential in the medical field. 3D printed amorphous metals can be used to manufacture personalized orthopedic implants, dental restorations, etc. These implants are not only strong and corrosion-resistant, but also can accurately match the patient’s anatomical structure, improving the success rate of surgery and patient comfort.

(3) Intelligent fields such as robotic manufacturing

Amorphous metal 3D printing process shows great potential in robotic manufacturing. Amorphous metal 3D printing technology can achieve rapid prototyping of complex structures and improve the integration and performance of robot components. The high strength and corrosion resistance of amorphous metals effectively enhance the durability and reliability of robots. In addition, the personalized customization capabilities of 3D printing provide more freedom for robot design, meet specific application requirements, and promote the development of robots towards lightweight and intelligent.

(4) Automobile industry

Amorphous metal 3D printing process can produce high-performance automotive parts such as engine housings and suspension systems. This can not only reduce vehicle weight and improve fuel efficiency, but also shorten the research and development cycle of new models. Through 3D printing, automobile manufacturers can quickly produce parts with complex structures and achieve small-batch customized production.

(5) Mold manufacturing

In the mold field, amorphous metal 3D printing process can produce injection molds with conformal cooling water channels. This mold can achieve more efficient cooling effects, shorten production cycles, and improve product molding quality. Through precise 3D printing technology, complex mold structures that are difficult to achieve with traditional processes can be manufactured.

(6) Sports equipment

Amorphous metal 3D printing process can be used to manufacture high-performance sports equipment, such as bicycle frames, golf clubs, etc. These equipment are not only light in weight and high in strength, but can also be customized according to the individual needs of athletes to improve sports performance and comfort.

8.Conclusion

Through the amorphous metal 3D printing process, complex structures and high-performance components that cannot be achieved by traditional manufacturing processes can be manufactured, improving product performance and reliability. Amorphous metal 3D printing process has not only promoted the upgrading of the manufacturing industry, but also brought technological innovation to high-precision and high-requirement fields such as aerospace, medical, and electronics.