Additive manufacturing of a nickel superalloy: The micromechanics of plasticity and fracture

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Significant efforts have been made to increase the efficiency of gas turbines and to reduce the emission of greenhouse gases. Likewise, the use of hydrogen is suggested to replace hydro-carbon-based fuels. To achieve these goals, it is mandatory to use advanced manufacturing techniques to produce the key components of turbines. Laser power bed fusion additive manufacturing (LPBF-AM) is one of those techniques that can be used for 3D printing of the Inconel superalloys used in gas turbines. However, depending on the LPBF-AM process parameters, microcracks form during 3D printing of the superalloy, reducing the lifetime of the components. The objectives of this project are to determine LPBF-AM process parameters to reduce such cracks and understand their subsequent effects on the development of localized stress fields. An advanced numerical toolbox will be developed to simulate the propagation of microcracks. The outcome of the project will help provide a better estimation of components lifetimes which will eventually improve the economy of power production from gas turbines.