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

Abstract

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.

Authors:
 [1]; ORCiD logo [2];  [3];  [4];  [1];  [1]; ORCiD logo [2]; ORCiD logo [2]; ORCiD logo [2]; ORCiD logo [2]; ORCiD logo [2]
  1. Univ. of Tennessee, Knoxville, TN (United States). Mechanical, Aerospace and Biomedical Engineering
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  3. Arconic, Pittsburgh, PA (United States)
  4. Oerlikon, Charlotte, NC (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1471909
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science
Additional Journal Information:
Journal Volume: 49; Journal Issue: 9; Journal ID: ISSN 1073-5623
Publisher:
ASM International
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

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, and Dehoff, Ryan R.. Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification. United States: N. p., 2018. Web. doi:10.1007/s11661-018-4702-4.
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.. Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification. United States. doi:10.1007/s11661-018-4702-4.
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, and Dehoff, Ryan R.. Fri . "Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification". United States. doi:10.1007/s11661-018-4702-4.
@article{osti_1471909,
title = {Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification},
author = {Babu, Sudarsanam Suresh and Raghavan, Narendran and Raplee, Jacob and Foster, Sarah J. and Frederick, Curtis and Haines, Michael and Dinwiddie, Ralph Barton and Kirka, Michael M. and Plotkowski, Alex J. and Lee, Yousub and Dehoff, Ryan R.},
abstractNote = {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.},
doi = {10.1007/s11661-018-4702-4},
journal = {Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science},
number = 9,
volume = 49,
place = {United States},
year = {Fri Jun 01 00:00:00 EDT 2018},
month = {Fri Jun 01 00:00:00 EDT 2018}
}

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Works referenced in this record:

Laser additive manufacturing of metallic components: materials, processes and mechanisms
journal, May 2012