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Title: Electrochemical Machining Technology for Surface Improvements of Ni-base Superalloy Additively Manufactured Components

Abstract

Additive Manufacturing’s (AM) promise and potential is of growing interest to US industries such as the energy sector. However, to move AM from prototyping to full-scale production a number of key risk areas must still be overcome, particularly the enhancing the surface finish of AM parts. Due to the industry’s desire for components fabricated from difficult to machine alloys and highly complex geometries, advanced finishing technologies are needed. This project focused on the ability to enhance the surface finish of material from the crack prone Ni-base superalloy Inconel 738 fabricated using the Arcam electron beam melting (EBM) process using the Pulsed Electrochemical Machining (PECM) process for surface enhancements. To evaluate the suitability of the PECM process, several artifacts were experimented with, each of which had increasing levels of complexity and relevancy to the industrial gas turbine sector. Ultimately, it was shown that the finish of as-built relevant EBM gas turbine airfoil surfaces could be enhanced by an average of 4x to approach an average roughness of a surface (Ra) equivalent of 1 um.

Authors:
ORCiD logo [1];  [2]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Voxel Innovations, Raleigh, NC (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1502544
Report Number(s):
ORNL/TM-2019/1083
NFE-17-06826
DOE Contract Number:  
AC05-00OR22725
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English

Citation Formats

Kirka, Michael, and Herrington, Daniel. Electrochemical Machining Technology for Surface Improvements of Ni-base Superalloy Additively Manufactured Components. United States: N. p., 2019. Web. doi:10.2172/1502544.
Kirka, Michael, & Herrington, Daniel. Electrochemical Machining Technology for Surface Improvements of Ni-base Superalloy Additively Manufactured Components. United States. doi:10.2172/1502544.
Kirka, Michael, and Herrington, Daniel. Fri . "Electrochemical Machining Technology for Surface Improvements of Ni-base Superalloy Additively Manufactured Components". United States. doi:10.2172/1502544. https://www.osti.gov/servlets/purl/1502544.
@article{osti_1502544,
title = {Electrochemical Machining Technology for Surface Improvements of Ni-base Superalloy Additively Manufactured Components},
author = {Kirka, Michael and Herrington, Daniel},
abstractNote = {Additive Manufacturing’s (AM) promise and potential is of growing interest to US industries such as the energy sector. However, to move AM from prototyping to full-scale production a number of key risk areas must still be overcome, particularly the enhancing the surface finish of AM parts. Due to the industry’s desire for components fabricated from difficult to machine alloys and highly complex geometries, advanced finishing technologies are needed. This project focused on the ability to enhance the surface finish of material from the crack prone Ni-base superalloy Inconel 738 fabricated using the Arcam electron beam melting (EBM) process using the Pulsed Electrochemical Machining (PECM) process for surface enhancements. To evaluate the suitability of the PECM process, several artifacts were experimented with, each of which had increasing levels of complexity and relevancy to the industrial gas turbine sector. Ultimately, it was shown that the finish of as-built relevant EBM gas turbine airfoil surfaces could be enhanced by an average of 4x to approach an average roughness of a surface (Ra) equivalent of 1 um.},
doi = {10.2172/1502544},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2019},
month = {1}
}

Technical Report:

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