Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

Babu, Sudarsanam Suresh; Raghavan, Narendran; Raplee, Jacob; Foster, Sarah J.; Frederick, Curtis; Haines, Michael; Dinwiddie, Ralph Barton; Kirka, Michael M.; Plotkowski, Alex J.; Lee, Yousub; Dehoff, Ryan R.

doi:10.1007/s11661-018-4702-4

Title: Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

Journal Article · Fri Jun 01 00:00:00 EDT 2018 · Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science

DOI:https://doi.org/10.1007/s11661-018-4702-4· OSTI ID:1471909

Babu, Sudarsanam Suresh ^[1];

^[2]; Raplee, Jacob ^[3]; Foster, Sarah J. ^[4]; Frederick, Curtis ^[1]; Haines, Michael ^[1];

^[2];

^[2]

Univ. of Tennessee, Knoxville, TN (United States). Mechanical, Aerospace and Biomedical Engineering
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Arconic, Pittsburgh, PA (United States)
Oerlikon, Charlotte, NC (United States)

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. Here 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.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1471909

Journal Information:: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science, Vol. 49, Issue 9; ISSN 1073-5623

Publisher:: ASM InternationalCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 101 works

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