A recent study published in Nature Communications marks a significant step forward in the manufacturing of titanium alloys, including using additive laser powder bed fusion, selective laser melting, and electron beam melting. Researchers have developed a method to predict and control grain structures in 3D-printed Ti-based alloys, resulting in titanium components that are approximately one-third cheaper to produce while maintaining or even improving their mechanical properties, tensile properties, and fatigue resistance. This achievement directly addresses a persistent challenge in the manufacturing of titanium components: ensuring consistent, high-quality microstructural properties. 

The Challenge in Metal Additive Manufacturing 

In powder bed fusion additive manufacturing, grain structure plays a decisive role in determining mechanical performance, including tensile behavior and fatigue behavior. Columnar grains tend to align in one direction, which can create weaknesses when stress is applied from other angles. Equiaxed grains, on the other hand, are more uniform in orientation, resulting in greater isotropy and improved performance. However, controlling the transition from columnar to equiaxed grains — known as the columnar-to-equiaxed transition (CET) — has been notoriously difficult to predict across additive manufacturing processes such as directed energy deposition and binder jetting printing. 

The Breakthrough Study 

The research team tackled this issue by identifying compositional parameters that can forecast and influence CET: 

Binary Ti-xCu (x from 0→25%) phase diagram generated using PANDATTM software with the PanTitaniumTM v2022 database. The representation of the ΔT_s (grey range), Q (blue range), and P (green range) values for Ti-6Cu from the phase diagram (Brooke et al., 2025).

By adjusting these parameters in titanium alloy formulations, the team consistently achieved equiaxed grain structures in 3D-printed Ti-based alloys, thereby improving microstructural properties and enabling better performance in biomedical implants and aerospace components. 

Advantages and Future Implications 

The newly designed alloy offers several notable advantages. First, it delivers cost efficiency, being approximately one-third cheaper than conventional titanium alloys. In terms of mechanical performance, it maintains or improves tensile properties, enhances isotropy, and offers superior fatigue resistance — addressing common weaknesses in traditional titanium prints. Its scalability means that the same compositional design approach can per alloy systems beyond titanium and applied across additive manufacturing methods, including energy deposition, additive processes, and adapted to other and electron beam melting. Finally, validation at RMIT University’s Advanced Manufacturing Precinct confirmed both the cost savings and the performance improvements, underscoring the method's real-world applicability. 

This discovery opens the door to more accessible titanium components in aerospace, medical, and industrial applications. By combining predictive compositional design with additive manufacturing processes such as powder bed fusion and selective laser melting, manufacturers can reduce costs without compromising quality. The principles demonstrated in this work can guide alloy development for a wide range of metal powders, potentially accelerating innovation across the sector. 

Final Thoughts 

The success of this research underscores a simple but powerful truth: in additive manufacturing, high-performance outcomes start with high-quality feedstock. The ability to control grain structure relies not just on process parameters and heat treatment, but also on the precision and consistency of the metal powders used. For researchers and manufacturers seeking to replicate or build upon such advances, MSE Supplies provides a comprehensive range of precision-engineered Metal Powders for 3D Printing and Additive Manufacturing, supporting projects from early-stage prototyping to full-scale production. 

Contact us today to request a quote or learn more about our additive manufacturing solutions. Visit our website, connect with us on LinkedIn, and subscribe to our newsletter for updates on the latest innovations and product offerings. 

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