Multiscale characterization of an additively manufactured property graded Ni-base alloy for molten-salts\supercritical-CO2 heat exchangers

Ren, Qing-Qiang; Su, Yi-Feng; Feldhausen, Thomas A.; Kurfess, Rebecca A.; Fillingim, Kenton B.; Nag, Soumya; Pillai, Rishi R.

doi:10.1016/j.matdes.2023.112560

Title: Multiscale characterization of an additively manufactured property graded Ni-base alloy for molten-salts\supercritical-CO₂ heat exchangers

Journal Article · 08 December 2023 · Materials & Design

DOI: https://doi.org/10.1016/j.matdes.2023.112560 · OSTI ID:2438996

^[1]; Su, Yi-Feng ^[2];

^[2]; Kurfess, Rebecca A. ^[2];

^[2];

^[2]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Center for Nanophase Materials Sciences (CNMS)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

The sequential optimization of strength and corrosion resistance in conventional alloy design procedures often results in a tradeoff between environmental degradation and optimal mechanical properties. A concurrent optimization of these two material properties is essential to efficiently develop high temperature alloys that can withstand harsh environments increasingly required for carbon–neutral energy technologies. In this work, we demonstrate the feasibility of directed energy deposition (DED) to manufacture a dual-corrosion resistant Ni-based alloy (Hastelloy N and Haynes 282), that meets the high temperature operation requirements of a molten-salts\supercritical-CO₂ (sCO₂) heat exchanger. A combination of multiscale characterization techniques and computational thermodynamics was employed to evaluate the cracking susceptibilities during fabrication and predict the microstructural stability of the material. Very good agreement was achieved between the observed and predicted phases and phase fractions of the as-printed material. A careful characterization of the transition zone between the two terminal alloy chemistries revealed potential precipitation strengthening (γ') on the Hastelloy N side while columnar-shaped M₂₃C₆ and γ' precipitates that formed at grain boundaries (GBs) of the transition zone likely minimized the local interfacial energies. Both these mechanisms are believed to increase the interfacial stability but their performance at high temperatures requires further investigation.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Center for Nanophase Materials Sciences (CNMS)

Sponsoring Organization:: USDOE Laboratory Directed Research and Development (LDRD) Program

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2438996

Journal Information:: Materials & Design, Journal Name: Materials & Design Vol. 237; ISSN 0264-1275

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (40)

Review of conceptual design and fundamental research of molten salt reactors in China Zhang, Dalin; Liu, Limin; Liu, Minghao International Journal of Energy Research, Vol. 42, Issue 5 https://doi.org/10.1002/er.3979	journal	January 2018
Computational Methods to Accelerate Development of Corrosion Resistant Coatings for Industrial Gas Turbines Pillai, R.; Kane, K.; Lance, M. Superalloys 2020 https://doi.org/10.1007/978-3-030-51834-9_81	book	January 2020
The role of alloying elements in the design of nickel-base superalloys Jena, A. K.; Chaturvedi, M. C. Journal of Materials Science, Vol. 19, Issue 10 https://doi.org/10.1007/BF00549796	journal	October 1984
Prediction of hot tearing tendency for multicomponent aluminum alloys Yan, Xinyan; Lin, Jen C. Metallurgical and Materials Transactions B, Vol. 37, Issue 6 https://doi.org/10.1007/BF02735013	journal	December 2006
Invited Review Paper in Commemoration of Over 50 Years of Oxidation of Metals: Addressing the Role of Water Vapor on Long-Term Stainless Steel Oxidation Behavior Pint, Bruce A. Oxidation of Metals, Vol. 95, Issue 5-6 https://doi.org/10.1007/s11085-020-10012-9	journal	January 2021
Identification of Mo-Rich M23C6 Carbides in Alloy 718 Aghajani, Ali; Tewes, Jürgen; Parsa, Alireza Basir Metallurgical and Materials Transactions A, Vol. 47, Issue 9 https://doi.org/10.1007/s11661-016-3593-5	journal	June 2016
Gamma Prime Stability in Haynes 282: Theoretical and Experimental Considerations Hawk, Jeffrey A.; Cheng, Tian-Le; Sears, John S. Journal of Materials Engineering and Performance, Vol. 24, Issue 11 https://doi.org/10.1007/s11665-015-1711-y	journal	September 2015
Microstructure and Hardness Evolution in Haynes 282 Nickel-Based Superalloy During Multi-variant Aging Heat Treatment Polkowska, Adelajda; Polkowski, Wojciech; Warmuzek, Małgorzata Journal of Materials Engineering and Performance, Vol. 28, Issue 7 https://doi.org/10.1007/s11665-019-3886-0	journal	January 2019
Overview on Recent Developments of Bondcoats for Plasma-Sprayed Thermal Barrier Coatings Naumenko, D.; Pillai, R.; Chyrkin, A. Journal of Thermal Spray Technology, Vol. 26, Issue 8 https://doi.org/10.1007/s11666-017-0649-z	journal	October 2017
Alloy design strategies for promoting protective oxide-scale formation Brady, M. P.; Wright, I. G.; Gleeson, B. JOM, Vol. 52, Issue 1 https://doi.org/10.1007/s11837-000-0109-x	journal	January 2000
Corrosion of Structural Alloys in High-Temperature Molten Fluoride Salts for Applications in Molten Salt Reactors Zheng, Guiqiu; Sridharan, Kumar JOM, Vol. 70, Issue 8 https://doi.org/10.1007/s11837-018-2981-2	journal	June 2018
High temperature coatings for gas turbine blades: A review Sivakumar, R.; Mordike, B. L. Surface and Coatings Technology, Vol. 37, Issue 2 https://doi.org/10.1016/0257-8972(89)90099-6	journal	April 1989
Thermo-Calc & DICTRA, computational tools for materials science Andersson, J-O; Helander, Thomas; Höglund, Lars Calphad, Vol. 26, Issue 2 https://doi.org/10.1016/S0364-5916(02)00037-8	journal	June 2002
Additive manufacturing of a functionally graded material from Ti-6Al-4V to Invar: Experimental characterization and thermodynamic calculations Bobbio, Lourdes D.; Otis, Richard A.; Borgonia, John Paul Acta Materialia, Vol. 127 https://doi.org/10.1016/j.actamat.2016.12.070	journal	April 2017
Computational thermodynamics and its applications Liu, Zi-Kui Acta Materialia, Vol. 200 https://doi.org/10.1016/j.actamat.2020.08.008	journal	November 2020
Modelling of additive manufacturability of nickel-based superalloys for laser powder bed fusion Xu, Jinghao; Kontis, Paraskevas; Peng, Ru Lin Acta Materialia, Vol. 240 https://doi.org/10.1016/j.actamat.2022.118307	journal	November 2022
Exploring Alloy Design Pathway Through Directed Energy Deposition of Powder Mixtures: A Study of Stainless Steel 316L and Inconel 718 Sargent, Noah; Wang, Yuankang; Li, Daozheng Additive Manufacturing Letters, Vol. 6 https://doi.org/10.1016/j.addlet.2023.100133	journal	July 2023
Modeling carbide dissolution in alloy 602 CA during high temperature oxidation Chyrkin, A.; Pillai, R.; Ackermann, H. Corrosion Science, Vol. 96 https://doi.org/10.1016/j.corsci.2015.03.019	journal	July 2015
Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions Agrawal, Ankur K.; Rankouhi, Behzad; Thoma, Dan J. Current Opinion in Solid State and Materials Science, Vol. 26, Issue 6 https://doi.org/10.1016/j.cossms.2022.101024	journal	December 2022
Liquid Metal as a Heat Transport Fluid for Thermal Solar Power Applications Frazer, D.; Stergar, E.; Cionea, C. Energy Procedia, Vol. 49 https://doi.org/10.1016/j.egypro.2014.03.068	journal	January 2014
Alumina-forming austenitic stainless steel for high durability and chromium-evaporation minimized balance of plant components in solid oxide fuel cells Zhou, Lingfeng; Brady, Michael P.; Li, Wenyuan International Journal of Hydrogen Energy, Vol. 47, Issue 90 https://doi.org/10.1016/j.ijhydene.2022.09.010	journal	November 2022
Materials corrosion in molten LiF–NaF–KF salt Olson, Luke C.; Ambrosek, James W.; Sridharan, Kumar Journal of Fluorine Chemistry, Vol. 130, Issue 1 https://doi.org/10.1016/j.jfluchem.2008.05.008	journal	January 2009
Opportunities and challenges in additive manufacturing of functionally graded metallic materials via powder-fed laser directed energy deposition: A review Ansari, M.; Jabari, E.; Toyserkani, E. Journal of Materials Processing Technology, Vol. 294 https://doi.org/10.1016/j.jmatprotec.2021.117117	journal	August 2021
First steps toward predicting corrosion behavior of structural materials in molten salts Pillai, R.; Raiman, S. S.; Pint, B. A. Journal of Nuclear Materials, Vol. 546 https://doi.org/10.1016/j.jnucmat.2020.152755	journal	April 2021
A comparison of the microstructure and creep behavior of cold rolled HAYNES® 230 alloy™ and HAYNES® 282 alloy™ Boehlert, C. J.; Longanbach, S. C. Materials Science and Engineering: A, Vol. 528, Issue 15 https://doi.org/10.1016/j.msea.2011.03.019	journal	June 2011
Microstructure and mechanical properties of direct laser metal deposited Haynes 282 superalloy Ramakrishnan, A.; Dinda, G. P. Materials Science and Engineering: A, Vol. 748 https://doi.org/10.1016/j.msea.2019.01.101	journal	March 2019
Additive manufacturing of functionally graded materials: A review Zhang, Chi; Chen, Fei; Huang, Zhifeng Materials Science and Engineering: A, Vol. 764 https://doi.org/10.1016/j.msea.2019.138209	journal	September 2019
Evaluation of additive electron beam melting of haynes 282 alloy Unocic, K. A.; Kirka, M. M.; Cakmak, E. Materials Science and Engineering: A, Vol. 772 https://doi.org/10.1016/j.msea.2019.138607	journal	January 2020
Experimental validation of Scheil–Gulliver simulations for gradient path planning in additively manufactured functionally graded materials Bocklund, Brandon; Bobbio, Lourdes D.; Otis, Richard A. Materialia, Vol. 11 https://doi.org/10.1016/j.mtla.2020.100689	journal	June 2020
The effect of applied stress on the high-temperature creep behaviour and microstructure of NiMoCr Hastelloy-N® alloy Zhu, Hanliang; Muránsky, Ondrej; Wei, Tao Materialia, Vol. 16, p. 101069 https://doi.org/10.1016/j.mtla.2021.101069	journal	May 2021
Evaluating the efficacy of aluminide coatings to improve oxidation resistance of high performance engine valve alloys Pillai, R.; Dryepondt, S.; Armstrong, B. L. Surface and Coatings Technology, Vol. 421 https://doi.org/10.1016/j.surfcoat.2021.127401	journal	September 2021
HAYNES 244 alloy – a new 760^∘C capable low thermal expansion alloy Fahrmann, Michael G.; Srivastava, S. Krishna; Pike, Lee M. MATEC Web of Conferences, Vol. 14 https://doi.org/10.1051/matecconf/20141417004	journal	January 2014
Corrosion behavior of wire arc sprayed Ni-based coatings in extreme environment Kumar, Manoj; Kant, Shashi; Kumar, Santosh Materials Research Express, Vol. 6, Issue 10 https://doi.org/10.1088/2053-1591/ab3bd8	journal	August 2019
HAYNES® 282™ Alloy: A New Wrought Superalloy Designed for Improved Creep Strength and Fabricability Pike, L. M. ASME Turbo Expo 2006: Power for Land, Sea, and Air, Volume 4: Cycle Innovations; Electric Power; Industrial and Cogeneration; Manufacturing Materials and Metallurgy https://doi.org/10.1115/GT2006-91204	conference	September 2008
A new computational approach for modelling the microstructural evolution and residual lifetime assessment of MCrAlY coatings Pillai, R.; Sloof, W. G.; Chyrkin, A. Materials at High Temperatures, Vol. 32, Issue 1-2 https://doi.org/10.1179/0960340914Z.00000000063	journal	January 2015
Concentrating Solar Power Gen3 Demonstration Roadmap Mehos, Mark; Turchi, Craig; Vidal, Judith https://doi.org/10.2172/1338899	report	January 2017
Microstructural Evolution in Cast Haynes 282 for Application in Advanced Power Plants Yang, Y.; Thomson, R. C.; Leese, R. M. Advances in Materials Technology for Power Plants https://doi.org/10.31399/asm.cp.am-epri-2013p0143	conference	October 2013
Review on the Corrosion Behaviour of Nickel-Based Alloys in Supercritical Carbon Dioxide under High Temperature and Pressure Kang, Yiyao; Leng, Xuesong; Zhao, Lin Crystals, Vol. 13, Issue 5 https://doi.org/10.3390/cryst13050725	journal	April 2023
Analysis of Corrosion of Hastelloy-N, Alloy X750, SS316 and SS304 in Molten Salt High-Temperature Environment Sandhi, Ketan Kumar; Szpunar, Jerzy Energies, Vol. 14, Issue 3 https://doi.org/10.3390/en14030543	journal	January 2021
Processing of Haynes® 282® Alloy by Direct Energy Deposition with Arc and Wire Zinke, Manuela; Burger, Stefan; Jüttner, Sven Materials, Vol. 16, Issue 4 https://doi.org/10.3390/ma16041715	journal	February 2023

Similar Records

Location-Specific Microstructures and Properties of Haynes 282 Alloy with Laser-Wire DED Processing

Conference · 2025 · OSTI ID:2538008

Feng, Rui; Tippey, Kristin; Poplawsky, Jonathan; +3 more

CALPHAD-based ICME design of single-step aging to enhance mechanical strength of WAAM Haynes 282

Journal Article · 2025 · Materials Science and Engineering: A · OSTI ID:2998395

Pizano, Luis Fernando Ladinos; Sudbrack, Chantal; Xiong, Wei

The performance of additively manufactured Haynes 282 in supercritical CO₂

Journal Article · 2022 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing · OSTI ID:1977468

Magnin, Collin; Islam, Zahabul; Elbakhshwan, Mohamed; +3 more

Related Subjects

36 MATERIALS SCIENCE
Additive manufacturing
Directed Energy Deposition (DED)
Hastelloy N and Haynes 282
Ni-base alloys
Precipitation

Title: Multiscale characterization of an additively manufactured property graded Ni-base alloy for molten-salts\supercritical-CO2 heat exchangers

Citation Formats

References (40)

Similar Records

Related Subjects

Title: Multiscale characterization of an additively manufactured property graded Ni-base alloy for molten-salts\supercritical-CO₂ heat exchangers