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Title: Final Scientific Technical Report for Project Title: Large Parts Additive Manufacturing

Abstract

Currently, fossil fuel is still the main source for energy production. The efficiency of the latter may be significantly improved by modern technologies such as chemical looping combustion, pressurized combustion, supercritical CO2 cycles, and direct power extraction. The processes of fossil fuel energy production require using high temperatures and thus, chemically stable materials resistant against creep, wear, and high temperature oxidation. Such energy production processes often occur in large scale machines/apparatus with big size componentry made from high temperature alloys. One of the most effective approaches to make parts from high temperature alloys is additive manufacturing (AM), which allows for economical build of near net shape pieces from high quality materials. One of the most usable alloys that meet the requirements to the turbine materials is Incoloy 718. During the project performance period the feasibility of the approach to produce large size (any axis is greater than 4 feet) parts from this material with mechanical properties not lower than those for commercially available alloy 718 by Plasma Transferred Arc Additive Manufacturing has been demonstrated; the processing parameters to PTA deposit alloy 718 blocks and round rods have been established. The mechanical properties of PTA deposited and heat treated at ATS-MERmore » alloy 718 are greater than those listed in Special Metals spec for the same heat treated Inconel 718 plates, forged bars, and wire welds. A tie-rod prototype 58” long x 1.9” OD has been deposited and machined. Tie-rods with any reasonable for this application diameters and lengths may be deposited with PTA. PTA deposition of 4 feet in diameter disk prototype has been prepared.« less

Authors:
 [1]
  1. ATS-MER, LLC
Publication Date:
Research Org.:
ATS-MER, LLC
Sponsoring Org.:
USDOE Office of Science (SC)
OSTI Identifier:
1494070
Report Number(s):
DOE-ATS-MER-18856-F
DOE Contract Number:  
SC0018856
Type / Phase:
SBIR (Phase I)
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; Plasma Transferred Arc, Additive Manufacturing, High Temperature Alloy, Inconel 718

Citation Formats

Dyadko, Eugene. Final Scientific Technical Report for Project Title: Large Parts Additive Manufacturing. United States: N. p., 2019. Web.
Dyadko, Eugene. Final Scientific Technical Report for Project Title: Large Parts Additive Manufacturing. United States.
Dyadko, Eugene. Mon . "Final Scientific Technical Report for Project Title: Large Parts Additive Manufacturing". United States.
@article{osti_1494070,
title = {Final Scientific Technical Report for Project Title: Large Parts Additive Manufacturing},
author = {Dyadko, Eugene},
abstractNote = {Currently, fossil fuel is still the main source for energy production. The efficiency of the latter may be significantly improved by modern technologies such as chemical looping combustion, pressurized combustion, supercritical CO2 cycles, and direct power extraction. The processes of fossil fuel energy production require using high temperatures and thus, chemically stable materials resistant against creep, wear, and high temperature oxidation. Such energy production processes often occur in large scale machines/apparatus with big size componentry made from high temperature alloys. One of the most effective approaches to make parts from high temperature alloys is additive manufacturing (AM), which allows for economical build of near net shape pieces from high quality materials. One of the most usable alloys that meet the requirements to the turbine materials is Incoloy 718. During the project performance period the feasibility of the approach to produce large size (any axis is greater than 4 feet) parts from this material with mechanical properties not lower than those for commercially available alloy 718 by Plasma Transferred Arc Additive Manufacturing has been demonstrated; the processing parameters to PTA deposit alloy 718 blocks and round rods have been established. The mechanical properties of PTA deposited and heat treated at ATS-MER alloy 718 are greater than those listed in Special Metals spec for the same heat treated Inconel 718 plates, forged bars, and wire welds. A tie-rod prototype 58” long x 1.9” OD has been deposited and machined. Tie-rods with any reasonable for this application diameters and lengths may be deposited with PTA. PTA deposition of 4 feet in diameter disk prototype has been prepared.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2019},
month = {2}
}

Technical Report:
This technical report may be released as soon as February 11, 2023
Other availability
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