1. New Technology Sets Records, Research Team Achieves Significant Results
On August 22, 2025, the Institute of Metal Research of the Chinese Academy of Sciences announced a major breakthrough, successfully developing a new type of 3D printing post-processing technology that produces titanium alloy materials with ‘all-purpose’ fatigue resistance, setting a new world record for the fatigue resistance of metal materials. The related results were published in Science Advances, with Dr. Qu Zhan as the first author and researchers Zhang Zhenjun, Liu Rui, and Zhang Zhefeng as co-corresponding authors. This achievement reveals the inherent advantages of 3D printed titanium alloy components in fatigue resistance, laying the foundation for applications in aerospace and other fields, and providing new ideas for optimizing the fatigue performance design of forged titanium alloys.
2. The Potential of 3D Printing is Great, but Fatigue Issues Remain to be Solved
3D printing, with its ability for free-form shaping, can meet the lightweight and high integration demands of the next generation of aerospace equipment, and is expected to replace traditional manufacturing to achieve intelligent manufacturing of key components for high-end equipment. However, for a long time, the fatigue performance of additive manufacturing materials and components has been poor, limiting its application prospects. In February 2024, the team at the Institute of Metal Research proposed the NAMP process, producing ultra-high tensile fatigue performance near void-free 3D printed Ti-6Al-4V alloy materials, breaking world records and changing people’s inherent perceptions of the fatigue performance of 3D printed materials.
3. Complex Stress Ratios, Full Stress Ratio Fatigue Resistance is Key
Actual engineering components operate in complex environments, and changes in stress ratios can alter the cyclic stress amplitude and maximum stress distribution ratio, inducing different fatigue crack initiation mechanisms. Traditional titanium alloy microstructures struggle to maintain excellent fatigue performance across the full range of stress ratios, as a single microstructural type often only has advantages within specific stress ratio ranges. For additively manufactured components with complex structures, the stress distribution is more complicated, bearing variable stress ratio fatigue loads, making high fatigue resistance under full stress ratio conditions a key challenge for the large-scale application of additive manufacturing technology in aerospace and other fields.
4. Revealing Weaknesses and Proposing Strategies, New Alloy Exhibits Outstanding Performance
The materials fatigue and fracture research team revealed three typical ‘fatigue weaknesses’ of titanium alloys and their stress ratio sensitive intervals, discovering that near void-free net additive manufacturing (Net-AM) microstructures can synergistically optimize these three weaknesses, proposing that 3D printed titanium alloys possess inherent high fatigue resistance characteristics under full stress ratio conditions. Based on the NAMP process, the team produced near void-free Net-AM Ti-6Al-4V alloy, and through extensive data comparison and analysis, its fatigue strength across the full stress ratio range is overall superior to all titanium alloy materials, and its fatigue strength is also comprehensively superior to all metal materials.
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