Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification
- PDF / 4,107,884 Bytes
- 17 Pages / 593.972 x 792 pts Page_size
- 56 Downloads / 281 Views
Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification S.S. BABU, N. RAGHAVAN, J. RAPLEE, S.J. FOSTER, C. FREDERICK, M. HAINES, R. DINWIDDIE, M.K. KIRKA, A. PLOTKOWSKI, Y. LEE, and R.R. DEHOFF Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can be used for repair and reclamation of nickel alloy components. The current paper explores opportunities for innovation and qualification challenges with respect to deployment of AM as a disruptive manufacturing technology. In the first part of the paper, fundamental correlations of processing parameters to defect tendency and microstructure evolution will be explored using DED process. In the second part of the paper, opportunities for innovation in terms of site-specific control of microstructure during processing will be discussed. In the third part of the paper, challenges in qualification of AM parts for service will be discussed and potential methods to alleviate these issues through in situ process monitoring, and big data analytics are proposed. https://doi.org/10.1007/s11661-018-4702-4 The Minerals, Metals & Materials Society and ASM International 2018
I.
INTRODUCTION
ADDITIVE manufacturing (AM) is considered to be a disruptive technology[1] by enabling engineers to make complex-shaped component with a simple process flow that transitions from computer-aided design file to final part, rapidly.[2–4] Based on this capability, innovative designs for turbine can be achieved by adopting AM for nickel-based superalloys.[5] AM may also provide advantage by influencing heat transfer and pressure loss within the turbine components by incorporating wavy microchannels.[6] Furthermore, AM also leads to unique surface properties due to spatial variations in melt pool shapes, e.g., in contour melting, and will influence gas flow through the channels.[7] It is well known that advanced geometries, e.g., shaped film cooling, will lead to improved performance.[8] In this regard, electron beam–powder bed fusion (E-PBF)[9–11] and laser
S.S. BABU, C. FREDERICK, and M. HAINES are with Mechanical, Aerospace and Biomedical Engineering, The University of Tennessee, Knoxville, 407 Dougherty Engineering Building, 1512 Middle Drive, Knoxville, TN 37934. Contact e-mail: [email protected] N. RAGHAVAN, R. DINWIDDIE, M.K. KIRKA, A. PLOTKOWSKI, Y. LEE, and R.R. DEHOFF are with the Oak Ridge National Laboratory, Oak Ridge, TN. J. RAPLEE is with Arconic, Pittsburg, PA. S.J. Foster is with Oerlikon, Charlotte, NC. Manuscript submitted March 25, 2018. Article published online June 1, 2018 3764—VOLUME 49A, SEPTEMBER 2018
beam–powder bed fusion (L-PBF)[12,13] have shown the potential for processing of nickel-based superalloys.[14,15] Th
Data Loading...
