# CAREER: Advancing the Printability of Aluminum Alloys via In-situ Alloying and Hybrid Processing Strategies

> **NSF 01002627DB NSF RESEARCH & RELATED ACTIVIT** · Iowa State University (IA) · $550,000

## Abstract

This Faculty Early Career Development Program (CAREER) award supports the NSF mission of securing national defense, with the aim of advancing the printability of aluminum (Al) alloys which are utilized heavily in structural applications in the naval and aerospace sectors. Printed aluminum components have the potential to enable increased fuel efficiency and enhance resistance to stress corrosion cracking compared to steel counterparts.  Laser powder blown Directed Energy Deposition (L-DED) is a popular metal additive manufacturing (AM) technique due to its capabilities to repair metal components and fabricate large scale parts with high deposition rate. However, only a small percentage of alloys can be reliably manufactured using AM process which hinders widespread industrial deployment of the process. One of the major reasons behind this challenge is solidification cracking. Many high-performance alloys, including aluminum, nickel-based alloys, and refractory alloys, have high cooling rates, thermal gradients and tensile residual stress which contribute to solidification cracking during AM-based processing. The goal of this CAREER project is to first understand the crack initiation and propagation mechanisms in L-DED processed Al and establish new strategies, guided by deposition science and based on laser-material interactions, to resolve these challenges. 

Major difficulties related to L-DED processing of Al are solidification cracking induced by tensile residual stress, large solidification range and poor aluminum melt fluidity. Research activities will be pursued systematically to reveal the interrelationship between macro-cracks and porosities along with crack nucleation and propagation mechanisms.  Strategic ‘in-situ’ alloying efforts will be pursued to advance scientific understanding about the individual effect of select alloying elements that can tune melt fluidity, solidification range and powder flowability synergistically reducing the defects in depo

## Key facts

- **NSF award ID:** 2542988
- **Awardee organization:** Iowa State University (IA)
- **SAM.gov UEI:** DQDBM7FGJPC5
- **PI:** Sougata Roy
- **Primary program:** 01002627DB NSF RESEARCH & RELATED ACTIVIT
- **All programs:** CAREER-Faculty Erly Career Dev, MATERIALS PROCESSING AND MANFG, Materials Engineering, Advanced Materials Processing, Advanced Manufacturing, EXP PROG TO STIM COMP RES, UNDERGRADUATE EDUCATION, GRADUATE INVOLVEMENT, MANUFACTURING
- **Estimated total:** $550,000
- **Funds obligated:** $550,000
- **Transaction type:** Standard Grant
- **Period:** 08/01/2026 → 07/31/2031

## Primary source

NSF Award Search: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2542988

## Citation

> US National Science Foundation, Award 2542988, CAREER: Advancing the Printability of Aluminum Alloys via In-situ Alloying and Hybrid Processing Strategies. Retrieved via AI Analytics 2026-07-09 from https://api.ai-analytics.org/grant/nsf/2542988. Licensed CC0.

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