Analysis of the interaction between hydrogen-based combustion systems, hightemperaturematerials and laser-based additive manufacturing (H2MAT3D)

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The efficiency of modern hydrogen-based combustion systems depends heavily on the flame-solid interactions since both the thermo-kinetic field inside the flame and the heat loss via the solid material strongly affect the flame stability. Furthermore, realization of novel geometrically complex burner designs can only be accomplished using additive manufacturing (AM) techniques. In H2MAT3D, the interaction between hydrogen-based combustion systems and additively manufactured materials is investigated experimentally and numerically. This will allow to bridge the gap between the design of AM burners and the process-material interaction in the combustion process. In order to achieve this, high-temperature resistant materials that are also processable by AM, in particular Laser Powder Bed Fusion (LPBF), are identified via thermodynamics-based alloy selection parting from Ni-base superalloys and produced via Extreme High-Speed Laser Application (EHLA), which enables a high-throughput alloy development. This work is supported by microstructure simulations that will contribute information factors influencing the high-temperature strength, degradation behavior and crack formation during additive manufacturing. The produced samples are studied in hydrogen combustion experiments and characterized pre- and post-operando to reveal degradation mechanisms. The experimental work on combustion is complemented by combustion simulations which aim to understand the influence of the material on the flame due to heat conductivity and surface reactions. The fundamental understanding gained in H2MAT3D will be used to harmonize the AM process conditions and high-temperature materials to yield combustion processes with enhanced efficiency. The results of this proposed research can be used for additive manufactured combustion systems in which tailored alloys and complex geometries help to increase the efficiency and to decrease the environmental impact of combustion processes.