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

这个小型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。尽管氢气的废气排放量为零，但由于与天然气相比，氢气的火焰温度更高，而且与合金的反应活性更高，因此它构成了挑战。该项目专注于开发一种高温合金系统，通过添加制造来制造，确保在氢气燃烧环境中使用寿命和可靠性。通过调整正在申请专利的热处理工艺，该项目旨在提高该合金的材料性能，用于耐用的售后服务部件，如叶片、叶片、裹尸布和面板部件。这些部件的性能可以超过现有精密熔模铸件，对于将工业燃气轮机转换为高效燃烧氢气至关重要，目前美国很大一部分热电联产和全球发电量都由这些部件提供动力。碳减排潜力是巨大的，一个目标部门的转换能够减少超过1千吨的二氧化碳排放。这项创新延伸到制造用于航空航天喷气发动机维修和大修的先进、高价值部件，为第三年带来2000万美元的潜在生产收入，并为燃气轮机中难以找到来源的部件提供关键的供应基础弹性。这个小型企业创新研究第一阶段项目旨在推进可添加制造的高温合金研究，重点是工业燃气轮机中氢气燃烧的应用。该项目将使用一种含有氧化物弥散强化成分的合金成分来制造机械和环境测试样品，该成分专门设计用于承受反应氢条件。测试将包括蠕变抗力、低周疲劳和氢脆等关键性能。一个关键的方面涉及通过定向热处理对合金进行后处理，并修改合金的晶粒结构以提高蠕变抗力，这在叶片段、护罩、叶片和燃气轮机部件的高温运行中至关重要。研究表明，与现有的添加制造的高温合金和精密熔模铸造等价物相比，其性能更优越。该项目的目标包括优化合金，改善制造条件，并获得服务条件的关键性能数据。初步设计曲线数据将被建立，为制造用于热火测试和改装成真实燃气轮机的部件提供便利。这一倡议承诺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气燃烧技术方面。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势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.