SBIR Phase I: Advanced Manufacturing of Oxide Dispersion-Strengthened Superalloys for High Temperature Creep and Hydrogen Environment Applications

这个小企业创新研究第一阶段项目的更广泛影响是推进燃气轮机发电的转换，以利用可持续的氢气作为燃料。虽然氢提供零废气排放，但与天然气相比，由于其更高的火焰温度和与合金的反应性，它带来了挑战。该项目的重点是开发一种高温合金系统，通过增材制造制造，确保在氢燃烧环境中的寿命和可靠性。通过扩大正在申请专利的热处理，该项目旨在提高合金的材料性能，用于耐用的售后零件，如叶片，叶片，叶片和面板段。这些组件可以超越现有精密熔模铸件的性能，对于转换工业燃气轮机以有效燃烧氢气至关重要，目前为美国热电联产和全球发电的重要部分提供动力。碳减排潜力很大，一个目标部门的转换能够减少1吨以上的二氧化碳排放量。该创新扩展到制造用于航空喷气发动机维修和大修的先进高价值部件，第三年的潜在生产收入为2000万美元，并为燃气轮机中难以采购的部件提供关键的供应基础弹性。该小型企业创新研究第一阶段项目旨在推进增材制造的高温合金研究，重点关注工业燃气轮机中氢气燃烧的应用。该项目将使用含有氧化物弥散强化成分的合金组合物制造机械和环境测试样本，该合金组合物专门设计用于承受活性氢条件。测试将包括关键性能，如抗蠕变性，低周疲劳和氢脆。一个关键方面涉及通过定向热处理和修改晶粒结构来对合金进行后处理以增强抗蠕变性，这在导叶段、涡轮、叶片和燃气涡轮机部件的高温操作中是至关重要的。研究表明，与现有的增材制造的高温合金和精密熔模铸造等效物相比，其具有优越的上级性能。该项目的目标包括优化合金，改善制造条件，并获得服务条件下的关键性能数据。初步设计曲线数据将被建立，以便于制造部件进行热点火试验和改装成真实的燃气涡轮机发动机。这一举措有望在高温合金能力方面取得重大进展，特别是在推进工业燃气轮机中的氢燃烧技术方面。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact of this Small Business Innovation Research Phase I project is to advance the conversion of gas turbines for power generation to utilize sustainable hydrogen as a fuel. Although hydrogen offers zero exhaust emissions, it poses challenges due to its higher flame temperature and reactivity with alloys compared to natural gas. This project focuses on developing a high-temperature alloy system, fabricated through additive manufacturing, ensuring longevity and reliability in hydrogen combustion environments. Through scaling a patent-pending thermal treatment, the project aims to enhance the alloy's material properties for durable aftermarket parts like vanes, blades, shrouds, and panel segments. These components can surpass the properties of existing precision investment castings and are essential for converting industrial gas turbines to efficiently burn hydrogen, currently powering a significant portion of US combined heat and power and global electricity generation. The carbon abatement potential is substantial, with the conversion of one targeted segment capable of reducing over 1 GT of CO2 emissions. The innovation extends to manufacturing advanced, high-value components for aerospace jet engine repair and overhaul, presenting a potential Year 3 production revenue of $20 million and providing critical supply base resiliency for hard-to-source components in gas turbines. This Small Business Innovation Research Phase I project aims to advance additively manufactured, high-temperature alloy research, focusing on applications in hydrogen combustion within industrial gas turbines. The project will fabricate mechanical and environmental test specimens using an alloy composition containing oxide dispersion-strengthening constituents designed specifically to withstand reactive hydrogen conditions. Testing will encompass critical properties like creep resistance, low cycle fatigue, and hydrogen embrittlement. A pivotal aspect involves post-processing the alloy through directional heat treatment and modifying the grain structure to enhance creep resistance, which is critical in the high-temperature operation of vane segments, shrouds, blades, and gas turbine components. Studies show superior properties compared to existing additively manufactured superalloys and precision investment cast equivalents. The project's objectives include optimizing the alloy, refining manufacturing conditions, and obtaining key performance data for service conditions. Preliminary design curve data will be established, facilitating the fabrication of components for hot-fire testing and retrofitting into real gas turbine engines. This initiative promises significant progress in high-temperature alloy capabilities, particularly for advancing hydrogen combustion technology in industrial gas turbines.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.