By applying machine learning techniques, engineers at MIT have created a new method for 3D printing metal alloys that produce parts far stronger than those made using traditional manufacturing approaches.
MIT engineers have created a new aluminum alloy designed for 3D printing that holds up under high heat and is five times stronger than aluminum made using conventional manufacturing.
To find the right formula, the researchers combined aluminum with other elements and used simulations alongside machine learning to narrow the search. Instead of running simulations on more than 1 million potential material combinations, as traditional approaches would require, their machine learning method reduced the workload to just 40 candidate compositions.
From those, they identified a promising blend aimed at producing a high-strength aluminum alloy that can be printed.After printing the new alloy and testing its performance, the team found the results matched their predictions. The material reached strength levels comparable to the strongest aluminum alloys currently produced through traditional casting techniques.
The researchers envision that the new printable aluminum could be made into stronger, more lightweight and temperature-resistant products, such as fan blades in jet engines. Fan blades are traditionally cast from titanium — a material that is more than 50 percent heavier and up to 10 times costlier than aluminum — or made from advanced composites.
