Researchers at Sandia Labs, Ames National Laboratory and Iowa State University reported a 3D-printed superalloy composed of 42% aluminum, 25% titanium, 13% niobium, 8% zirconium, 8% molybdenum and 4% tantalum. Most alloys are made chiefly of one primary element, combined with low amounts of other elements. In contrast MPES have substantial amounts of three or more elements.
Such alloys promise improvements on high-temperature applications, strength-to-weight, fracture toughness, corrosion and radiation resistance, wear resistance, and others. They reported hardness and density of 1.8–2.6 GPa-cm/g, which surpasses all known alloys, including intermetallic compounds, titanium aluminides, refractory MPEAs, and conventional Ni-based superalloys. This represents a 300% improvement over Inconel 718 based on measured peak hardness of 4.5 GPa and density of 8.2 g/cm, (0.55 GPa-cm/g).
The material is stable at 800 °C, hotter than the 570+ °C found in typical coal-based power plants.
The researchers acknowledged that the 3D printing process produces microscopic cracks when forming large parts, and that the feedstock includes metals that limit applicability in cost-sensitive applications.