Solid-state 3D printing, without melting, strong/ ductile aluminum parts, bypassing common structural cracking and porosity defects

https://www.eurekalert.org/news-releases/1132013

"liquid-to-solid metal 3D printing melting defects (cracking, micro-pores, and coarse grain boundaries) ruin high-strength aerospace alloys' structural properties, overcome via screw extrusion-plasticizing friction stir deposition to manufacture high-strength 5xxx-series aluminum alloys... utilizes 3-stage tapered screw tool to continuously feed, crush, plasticize particulate into multi-layer wall... scalable complex parts fabrication for advanced lightweight structures: automotive, marine, flight-ready aerospace"

Related:

New insights could help improve quality of 3D-printed aluminium components
https://www.eurekalert.org/news-releases/1136051

Heat treatment improves strength-ductility balance of 3D-printed aluminum bronze for electronic components
https://techxplore.com/news/2026-08-treatment-strength-ductility-3d-aluminum.html