[China Aluminum] The new progress of 3D printing may bring us lighter and faster aircraft. With the same amount of fuel, this aircraft can fly significantly farther.

Today's aircraft is assembled from thousands of metal rivets and various parts. This is because the aluminum alloy used for the frame is light and strong but it cannot be welded. Once you try to weld them, there is a phenomenon called hot cracking, which becomes brittle and breaks when it cools. Welding effects such as this also hinder the development of 3D printing in the direction of high-strength aluminum alloys. Researchers discovered after various attempts that the metal after laser melting would fall like a cracker.

However, everything seems to change soon. Researchers at the HRL lab in Malibu, Calif., seem to have overcome this long-standing problem after developing two more commonly used high-strength aluminum alloys for 3D printing.

These alloys can be used not only for aircraft but also for cars and trucks. In addition to this, this method also increases the possibility of using a 3D printing process to manufacture high-strength steels and nickel-base superalloys. On the other hand, the team's trick is to use special nanoparticles to make the metal coating and form the desired alloy microstructure framework when the laser heats the metal. As it cools, the molten alloy follows the crystallographic pattern set by these nanoparticles, preventing the occurrence of thermal cracking, which means that the finished product can maintain its complete physical characteristics. In order to find suitable nanoparticles, in particular zirconium-based nanoparticles. Researchers have finally found nanoparticles with corresponding properties through numerous possible elemental analyses on the periodic table.

Zirconium is not expensive and moderate manufacturing costs are expected to achieve high value applications. Welded aluminum planes may further reduce the weight of the aircraft. The lighter weight allows the aircraft to fly farther on the same amount of fuel, and these will become considerable profits and benefits later.

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