Development and characterization of high strength / high temperature powders compositions for additive manufacturing and repair applications

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Engine turbine components are made of high temperature resistant materials, typically nickel- or cobalt-based superalloys. During service, turbine parts can become damaged resulting in engine operation deficiencies and potential damage to subjacent components. High strength superalloy component manufacture and repair involves the usage of complex multicomponent alloy systems. This stems from the need to match alloy compositions, and for good weldability and mechanical properties. To date, there is a lack of knowledge and models addressing some of the key fundamental phenomenon involved during fabrication for such multicomponent systems. This explains why the current approaches to production are developed from a combination of industrial experience and know how, and costly and time-consuming trial and error approach. This proposal is designed to address the existing knowledge gaps for multicomponent alloy systems, to permit the development of a more rigorous and systematic approach for the design and optimisation of high temperature performance Additive Manufacturing-specific alloys and associated processing parameters. Liburdi Turbine Services (LTS), a division of Liburdi Engineering (Ontario), is the world leader in turbine MRO and turbine blade repair. They see this research as an avenue to maintaining their competitiveness and technological leadership by gaining a fundamental understanding combined with a multicomponent modeling toolkit. In this work, a better understanding of the relationships linking the melting point depressant concentration, and the evolving properties of the liquid as a function of soaking time during the heat treatment for two multicomponent superalloy systems (R142 and RN5) will be provided. Also, the possibility of using the exact powder blend composition, but under the framework of a homogeneous powder feedstock to be used in Laser Powder Bed Fusion and Direct Energy Deposition methods will be evaluated. Success in this objective would allow simplified in-situ repair, without the risks of compositional variation.