Researcher Conducts Multi-dimensional Testing of 3D Printed Nickel-based Superalloy Materials

(Researcher Conducts Multi-dimensional Testing of 3D Printed Nickel-based Superalloy Materials)

In the aerospace field, high-temperature alloy materials are used to
manufacture components in critical areas of jet turbine engines, such as
combustion chambers, high- and low-pressure turbine areas compressor rear ends.
All parts in these areas are exposed to high temperatures and higher levels of
oxidation.

Powder bed laser melting (L-PBF) metal 3D printing technology is highly
valued in the manufacture of high-value-added function integrated
high-temperature alloy parts, especially in manufacture high-temperature alloy
parts with integrated advanced cooling structure due to its advantages in the
manufacture of complex systems. The field has played a role that traditional
technology cannot play. Besides, high-temperature engine components are usually
costly. The L-PBF process can reduce material waste and shorten the lead time,
allowing manufacturers to benefit from inventory management. However, there are
still challenges for L-PBF in the additive manufacturing of superalloys. For
example, due to the strong temperature gradient, the metastable chemical,
structural, and mechanical states are caused, which results in metallurgical
defects that affect performance.

Nickel-based alloys are high-temperature alloy materials commonly used in
traditional manufacturing processes, such as IN738, IN713, and MarM247. However,
conventional nickel-based superalloy materials' chemical properties are not
compatible with laser melting 3D printing technology because they cannot respond
well to rapid thermal gradient changes. It is practically impossible to control
the amount of cracking during welding. Therefore, these alloy materials are
mostly processed by casting methods with relatively low cooling rates.

If aerospace manufacturing users want to use L-PBF 3D printing technology to
enhance high-temperature applications' competitive advantage, finding a
superalloy material specifically suitable for this 3D printing technology
without compromising structural integrity becomes a crucial part. According to
market observations from 3D Science Valley, Honeywell's testing of a new
nickel-based superalloy material-ABD-900AM is precisely promoting the
application of additive manufacturing of superalloys.

ABD-900AM is a nickel-based superalloy material developed by Alloyed for
powder bed laser melting 3D printing technology, which adds high-strength and
medium creeping components. The static strength is close to that of cast
IN-713C.

However, most conventional nickel-based superalloys cannot be used to
transition from a precision casting process to 3D printing technology because
these materials are optimized for traditional methods such as casting. Due to
the rapid repetitive thermal cycle of the 3D printing process, new components
for 3D printing process parameters can be designed in a data-driven way of
component calculation to adjust the microstructure and performance for the
additive's high cooling rate manufacturing. Therefore, optimizing nickel-based
superalloy materials for additive manufacturing processes, reducing their
metallurgical defects, and introducing alloy materials suitable for 3D printing
plays an essential role in promoting superalloy additive application
manufacturing.

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(Researcher Conducts Multi-dimensional Testing of 3D Printed Nickel-based Superalloy Materials)