Development of Additive Manufacturing Superalloys with high ?' volume fraction

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Summary The proposed research addresses the critical need to develop optimum high ' superalloys amenable for Additive Manufacturing (AM). Ni-based superalloys are known to have a complex chemistry, with over a dozen alloying elements in most alloys, enabling them to achieve outstanding high-temperature mechanical performance as well as oxidation resistance when processed using conventional routes (e.g., casting and forging). Nonetheless, this complex chemistry results in the formation of various phases that could affect their processability using AM, resulting in cracking and severe distortion in parts such as compressor veins and air foils, which are critical in the aero, energy, and defense sectors. To address this need, the proposed program of Discovery research will: 1. Understand the mechanisms associated with cracking during SEBM processing. Focusing on SEBM processing conditions for high ' superalloys and identifying “crack-safe” processing window. 2. Understand the mechanisms associated with cracking during SEBM post-processing. Focus will be on heat treatments following SEBM processing. These heat-treatments are required for high ' Superalloys to fully benefit their ' precipitation structure on mechanical properties. 3. Characterize and model cracking due to ductility dip in AM superalloys microstructures. Focus will be on rapidly cooled microstructures resulting from SEBM processing. This objective will initiate the long term objective to simulate cracking during SEBM. This research program proposes a combination of experiments, analytical theory, and computer simulations to explore the processing-structure-property relationships of AM superalloys. Advanced characterization techniques, mechanical testing, and advanced modeling approaches will be used to improve our understanding and accelerate the development of next generation of Superalloys suitable for AM. These the research will accelerate the development of future aircraft and gas turbine engines, more specifically the fabrication of complex geometry parts, enhancing the competitiveness of the Canadian aero, energy, and defence sectors. Four graduate students will be trained in state-of-the-art experimental and analytical techniques in the AM field. Their recruitment within Canadian industry and academe will further enhance Canada's future competitiveness.