The conventional method of using advanced metals in manufacturing is costly, since they tend to be difficult to sculpture. A Purdue University team created a method for applying a designer surface-active agent to the surface of a metal to make it easier to cut and shape the material into parts and pieces. It’s a growing industry – the global metal fabrication market value is expected to reach $24 billion by 2024.

 

Most people may not realise it but they encounter products made with exotic or advanced metals every day. The metals are used in aircraft, orthopedic components, medical instruments, cars, solar panels, military equipment and other applications, and are called advanced or exotic because they are more difficult to find and more costly to use in manufacturing.

 

“What we have created is a new way to approach the machining of these metals that has the potential to change manufacturing system processes. Our solution is showing great promise in making these metals more affordable to manufacture and process by making them easier to machine,” said Srinivasan Chandrasekar, a professor of industrial engineering in Purdue University’s College of Engineering.

 

Researchers at Purdue used common alcohols on an aluminium surface and were able to cut the metal more easily, with at least 50 per cent less force, and produce a smoother end surface with fewer cracks and tears compared with aluminium without the alcohol treatment.

“Purdue provides an extraordinary environment to conduct this kind of research that you will not find at most other universities. We have lab equipment and space to test our methods at the scale found in actual manufacturing industry facilities and spaces,” added Chandrasekar.

 

Chandrasekar said the same approach is showing promise for other metal systems such as stainless steel, tantalum, copper, iron and even nickel alloys. Each metal system requires a specific designer agent since alcohols do not interact with other metals in the same way as they do with aluminium.