The U.S. Army Research Laboratory (ARL) will collaborate with researchers from the University of Central Florida (UCF) to develop additive manufactured lighter weight weapons components for soldiers. The team will optimize the process parameters for the AM of a high-strength magnesium alloy. The lightweight alloy was used to fabricate 24 micro-lattice structures via laser powder bed fusion, allowing the characterization of its compressive strength and failure modes. The expectations are high-strength alloy will eventually be used in future military parts.

Magnesium AM lattice structures by UCF and ARL researchers. (Courtesy of UCF)

Novel process brings most reactive components to the surface (left) and traps the least reactive components at the core (right). (Courtesy Martin Thuo/Iowa State University)

Inspired by nature’s work to build spiky structures in caves, Iowa State University (ISU) researchers have developed a novel technology capable of recovering precious metals from the alloys in electrical waste, such as old phones, computers, and televisions. University start-up funds and part of a U.S. Department of Energy Small Business Innovation Research grant supported development of the technology.

At relatively low temperatures, oxygen is introduced, slowly moving most reactive surfaces to the surface forming stalagmite-like spikes of metal oxides.  The least-reactive components remain in a purified, liquid core surrounded by brittle metal-oxide spikes “to create a so-called ‘ship-in-a-bottle structure,’” said Martin Thuo, the leader of the research project and an associate professor of materials science and engineering at ISU.

ORNL researchers used Electron Beam Powder Bed Fusion to produce crack-free molybdenum, proving its viability for Additive Manufacturing. (Courtesy of ORNL/US Dept of Energy)

Oak Ridge National Laboratory, Oak Ridge, Tennessee, proved molybdenum titanium carbide, a refractory metal alloy that can withstand extreme temperature environments, can also be crack free and dense when produced with electron beam powder bed fusion. Molybdenum (Mo) and other refractory alloys are difficult to process through traditional manufacturing because of their high melting temperature, reactivity with oxygen and brittleness.
 

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GKN Automotive reports 13 new electrified models from 10 global brands will enter the market shortly.  The new platforms span four major global automotive manufacturers and range from premium four-wheel drive SUVs to small sedans. The innovative technologies on these models include GKN Automotive’s three in one eDrive systems. The eDrive systems bring together advances in electric motors, transmission, traction inverters, software and controls. The first car using GKN Automotive eDrive technology was put into production over 20 years ago.