Researchers at the National Institute of Standards and Technology (NIST) have developed a method to stir molten metal during laser powder bed fusion 3D printing, enabling the creation of high-entropy alloys. The technique involves directing the laser in loop-the-loop patterns to mix different metals as they melt.
Key Details
- The method was tested by combining a dense high-entropy alloy (RHEA-19) with a lightweight titanium alloy.
- The researchers used the Advanced Photon Source at Argonne National Laboratory to observe atomic structure changes in real time as the metal solidified.
- Electron microscopy was also used to examine the final product.
- The technique does not require new hardware and can be implemented on existing printers by modifying software.
Potential Applications
- Could enable on-demand alloying, reducing the need for multiple pre-mixed powders.
- May allow gradual alteration of alloy composition within a single part, such as jet turbine blades.
- Could lower costs and increase versatility in metal 3D printing.
This approach could fundamentally change how metal alloys are produced, allowing manufacturers to "dial in" specific material properties without changing their machines.
The research was published in Additive Manufacturing on January 30, 2026.