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Penn State University Fabricates Topology-Optimized Beams in 316L and CuCrZr via Multi-Material LPBF
2026-05-29
A joint research team at Pennsylvania State University designed multi-material MBB beams using an alternating active-phase algorithm and fabricated them via multi-material laser powder bed fusion (MM-LPBF) with 316L stainless steel and CuCrZr alloy. Measured stiffness deviated only 5.3% from finite element predictions. The dual-material interface exhibited defects characteristic of MM-LPBF, with mechanical tests showing failure initiating in the CuCrZr region and propagating to the interface. The method can be extended to applications requiring multi-objective optimization, such as heat exchangers, biomedical devices, and energy storage systems. Further development of MM-LPBF processes is needed to reduce bulk porosity and interface defects, as its processing physics differ significantly from single-material LPBF and other metal additive manufacturing processes.
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宾州大学多材料LPBF制备316L和CuCrZr拓扑优化梁
美国宾夕法尼亚州立大学的联合研究团队通过交替活性相算法设计多材料MBB梁，采用多材料激光粉末床熔融（MM-LPBF）成形316L不锈钢和CuCrZr合金，实测刚度与有限元预测偏差仅5.3%。双材料界面存在MM-LPBF特有的缺陷，力学测试显示失效从CuCrZr区域萌生并扩展至界面。该方法可扩展至换热器、生物医疗器件、储能装置等需多目标优化的应用。需进一步开发MM-LPBF工艺以减少体孔隙率和界面缺陷，因其加工物理与单材料LPBF及其他金属增材制造工艺差异显著。