SBIR Phase II: Reactive Additive Manufacturing of Advanced Superalloys for Turbine Engines

该SBIR第二阶段项目将解决添加剂制造所需的高温应用材料不足的问题。添加制造，通常称为3D打印，提供了更大的设计自由度和复杂的功能，如零件合并和保形冷却通道。通过将添加剂制造带来的设计改进与合适的高温材料相结合，可以提高燃气轮机和其他应用的性能和效率。遗憾的是，现有材料要么没有足够的高温性能，要么与高质量的打印方法不兼容。该项目将开发用于高温燃气轮机部件的新型镍高温合金复合添加剂制造材料。该项目的成功完成将带来更高效的涡轮机，以降低能源成本、运输成本和碳排放。预计制造业、发电和航空航天行业将受到该项目的影响。此外，历史证明，新材料和制造技术往往会带来更多意想不到的创新。该项目将帮助美国在高性能材料技术创新方面处于领先地位，以满足价值860亿美元的燃气轮机市场的需求，并在美国增加先进的制造工作岗位。该项目将利用创新的反应性添加剂制造材料技术来开发3D可打印的先进高温高温合金。在添加剂制造过程中，将在高温合金基质中原位合成高熔点产品相，以显著改善高温性能和改善印刷适性。这种创新的反应性添加剂制造技术已被证明适用于包括NSF一期项目中的镍高温合金在内的各种材料体系。与同类传统合金相比，采用该技术生产的金属基复合材料具有更高的强度、耐磨性和高温性能。此外，这项技术还证明了消除以前被认为不可印刷的合金的微观和宏观开裂问题的能力。该项目旨在进一步开发一种或多种与激光粉末床熔融添加剂制造兼容的高温合金，用于燃气轮机的高温部件。该项目的范围包括新材料原料的理论和实验开发和评估、添加剂制造工艺条件和热处理。印刷部件的评估将包括密度、硬度、标准和高温拉伸性能、蠕变、显微结构和物相分析的测量。该奖项反映了NSF的法定使命，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，被认为是值得支持的。

This SBIR Phase II project will address the lack of high application temperature materials available for additive manufacturing. Additive manufacturing, often called 3D printing, provides increased design freedom and complex features such as part consolidation and conformal cooling channels. The performance and efficiency of gas turbines and other applications can be increased by combining design improvements enabled by additive manufacturing with a suitable high temperature material. Unfortunately, existing materials either do not have sufficient high temperature performance or are not compatible with high quality printing methods. This project will develop new nickel superalloy composite additive manufacturing materials for use with high temperature gas turbine components. Successful completion of this project will result in more efficient turbines to reduce energy costs, transportation costs, and carbon emissions. The manufacturing, power generation, and aerospace industries are expected to be impacted from this project. In addition, history has demonstrated that new materials and manufacturing technologies often lead to additional unexpected innovations. This project will help the country lead in the innovation of high performance materials technology to address the needs of the $86 billion gas turbine market and to grow advanced manufacturing jobs in the US.This project will utilize innovative reactive additive manufacturing materials technology to develop 3D printable advanced high temperature superalloys. During additive fabrication, high melting temperature product phases will be synthesized in-situ within a superalloy matrix to significantly improve high temperature performance and improve printability. This innovative reactive additive manufacturing technology has been shown to be applicable to a wide range of materials systems including nickel superalloys in an NSF Phase I project. Metal matrix composites produced using this technology have demonstrated greatly increased strength, wear resistance, and high temperature performance relative to comparable traditional alloys. In addition, this technology has demonstrated the ability to eliminate micro and macro cracking problems with alloys that had previously been considered unprintable. This project aims to further develop one or more high temperature superalloys compatible with laser powder bed fusion additive manufacturing for use in the hot sections of gas turbines. The scope of the project includes theoretical and experimental development and evaluation of novel material feedstocks, additive manufacturing processing conditions, and heat treatments. Evaluation of printed components will include measurement of density, hardness, standard and high temperature tensile properties, creep, and microstructure and phase analysis. Turbine components will be additively fabricated for pilot studies.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.