3D Printing of Molybdenum Metal and Molybdenum-Based Alloys
Release time:
2025-09-01
Molybdenum metal is an indispensable material in many industries due to its strength at high temperatures. Some applications require complex shapes that are difficult to machine, making 3D printing a viable solution for producing intricate components. However, defects often arise when manufacturing such parts using molybdenum metal. A new process involving the alloying of molybdenum metal with titanium carbide may signal a turning point.
Printing Paradigm Shift
Highly specialized industrial components are increasingly produced through additive manufacturing (AM), also known as 3D printing. Originating in the mid-1980s, AM technology was initially used to accelerate product prototyping. The process involves fusing material layer by layer at the microscopic level. The “printer” references a computer 3D model to build an exact replica layer by layer. Unlike traditional “subtractive” manufacturing methods—milling, cutting, drilling, and grinding—successful additive manufacturing produces virtually no waste. Using AM to increase part complexity is often more cost-effective, as designs can be easily modified on a computer. Designs challenging or impossible to achieve with conventional manufacturing—such as hollow parts with no connection to the outer surface—can be realized through 3D printing.
The ability to 3D print molybdenum into complex shapes required by the aerospace, defense, and energy industries enhances thermal efficiency, ultimately meaning more electricity generated with fewer resources. However, a challenge lies in the potential loss of mechanical properties and stability in 3D-printed molybdenum, rendering it unusable. This occurs because 3D printing molybdenum and molybdenum alloys under improper conditions readily produces defects like porosity and cracks. Yet, by meticulously controlling the 3D printing process, stable, high-quality, crack-free parts can be produced using molybdenum and molybdenum-based alloys (such as titanium carbide-molybdenum-based alloys). Scientists at Oak Ridge National Laboratory (ORNL) in the southeastern United States are collaborating with external stakeholders to conduct scaled trials on molybdenum metal and molybdenum-based alloy objects. 3D printing enables the creation of complex shapes unattainable through other manufacturing methods.
No More Gaps
This manufacturing process employs an additive manufacturing technique called Powder Bed Fusion (PBF), which melts powdered raw materials into solid forms. PBF requires a laser or electron beam to melt and fuse powdered components. Researchers employed the latter method due to its superior control over temperature variations during printing. While PBF for molybdenum has yet to achieve industrial-scale success due to material susceptibility to defects during processing, recent findings suggest this will soon change.
Researchers demonstrated the ability to print high-quality molybdenum metal with a unique grain structure unattainable through conventional manufacturing processes. Advances in PBF processing technology enabled the successful printing of structural components for nuclear thermal propulsion systems.
Beyond pure molybdenum, researchers also successfully printed a matrix-based molybdenum-titanium carbide composite. In materials science terminology, these are termed cermets. To fabricate the cermets, researchers mechanically alloyed a mixture of 60% molybdenum powder and 40% titanium carbide powder before printing. No defects were detected post-printing. The successful production of such materials holds potential to advance energy systems requiring components to operate in extreme environments, such as supercritical carbon dioxide conditions.
Other research teams have also achieved promising results. In 2019, Beijing Institute of Technology developed 3D-printed molybdenum metal components for ion thrusters in the aerospace industry. The research group combined molybdenum metal powder with titanium carbide powder to form a stable, oxidation-resistant composite material. This composite approach appears to yield positive effects not only for pure molybdenum metal but also for other molybdenum-containing alloys. A Singaporean research team achieved good printability by blending titanium diboride nanoparticles with the molybdenum-containing nickel-based alloy INCONEL 625. These advances further demonstrate the feasibility of significantly enhancing the 3D printability of molybdenum metal and molybdenum-containing alloy components in the future. These projects showcase molybdenum's unique properties and its growing value in the global decarbonization process.
Improving the efficiency of thermal power plants, such as nuclear reactors, hinges on developing superior materials—particularly those exhibiting high-temperature strength. Molybdenum stands as arguably the prime candidate material for this endeavor. The ability to 3D-print materials into industrially required shapes could profoundly impact the goal of generating more power with less consumption.
References: (Source: IMOA Molybdenum and Molybdenum-Containing Materials Worldwide, May 31, 2022)
Stardust Technology employs radiofrequency plasma spheroidization technology to produce spherical molybdenum powder and molybdenum alloy powder. Its spherical molybdenum powder features controllable particle size distribution, high purity (>99.95%), low oxygen content, high sphericity, and excellent flowability, making it suitable for additive manufacturing processes such as SLM and EBM. Additionally, the company develops refractory high-entropy alloy powders including tungsten, molybdenum, tantalum, and niobium. These alloy powders exhibit outstanding high-temperature strength, creep resistance, and corrosion resistance, making them suitable for aerospace, medical implants, and other fields. With reliable product quality, they meet high-precision 3D printing requirements. For more product information, please contact our professional manager Cathie Zheng at +86 13318326187.
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