Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

S. S. Babu; N. Raghavan; J. Raplee; S. J. Foster; C. Frederick; M. Haines; R. Dinwiddie; M. K. Kirka; A. Plotkowski; Y. Lee; R. R. Dehoff

doi:10.1007/s11661-018-4702-4

Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

S. S. Babu, N. Raghavan, J. Raplee, S. J. Foster, C. Frederick, M. Haines, R. Dinwiddie, M. K. Kirka, A. Plotkowski, Y. Lee, R. R. Dehoff

Research output: Contribution to journal › Article › peer-review

156 Scopus citations

Abstract

Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can be used for repair and reclamation of nickel alloy components. The current paper explores opportunities for innovation and qualification challenges with respect to deployment of AM as a disruptive manufacturing technology. In the first part of the paper, fundamental correlations of processing parameters to defect tendency and microstructure evolution will be explored using DED process. In the second part of the paper, opportunities for innovation in terms of site-specific control of microstructure during processing will be discussed. In the third part of the paper, challenges in qualification of AM parts for service will be discussed and potential methods to alleviate these issues through in situ process monitoring, and big data analytics are proposed.

Original language	English
Pages (from-to)	3764-3780
Number of pages	17
Journal	Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
Volume	49
Issue number	9
DOIs	https://doi.org/10.1007/s11661-018-4702-4
State	Published - Sep 1 2018

Funding

This research is based upon work supported by the US Department of Energy, Office of Energy, Efficiency, and Renewable Energy, Advanced Manufacturing Office under Contract Number DE-AC05-00OR22725. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan energy.gov/ downloads/doe-public-access-plan http://energy.gov/downloads/doe-public-access-plan). Manuscript submitted March 25, 2018.

Funders	Funder number
DOE Public Access Plan
Office of Energy, Efficiency, and Renewable Energy, Advanced Manufacturing Office	DE-AC05-00OR22725
US Department of Energy
United States Government

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This output contributes to the following UN Sustainable Development Goals (SDGs)

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Babu, S. S., Raghavan, N., Raplee, J., Foster, S. J., Frederick, C., Haines, M., Dinwiddie, R., Kirka, M. K., Plotkowski, A., Lee, Y., & Dehoff, R. R. (2018). Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification. Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science, 49(9), 3764-3780. https://doi.org/10.1007/s11661-018-4702-4

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abstract = "Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can be used for repair and reclamation of nickel alloy components. The current paper explores opportunities for innovation and qualification challenges with respect to deployment of AM as a disruptive manufacturing technology. In the first part of the paper, fundamental correlations of processing parameters to defect tendency and microstructure evolution will be explored using DED process. In the second part of the paper, opportunities for innovation in terms of site-specific control of microstructure during processing will be discussed. In the third part of the paper, challenges in qualification of AM parts for service will be discussed and potential methods to alleviate these issues through in situ process monitoring, and big data analytics are proposed.",

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Babu, SS, Raghavan, N, Raplee, J, Foster, SJ, Frederick, C, Haines, M, Dinwiddie, R, Kirka, MK , Plotkowski, A , Lee, Y & Dehoff, RR 2018, 'Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification', Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science, vol. 49, no. 9, pp. 3764-3780. https://doi.org/10.1007/s11661-018-4702-4

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AU - Babu, S. S.

AU - Raghavan, N.

AU - Raplee, J.

AU - Foster, S. J.

AU - Frederick, C.

AU - Haines, M.

AU - Dinwiddie, R.

AU - Kirka, M. K.

AU - Plotkowski, A.

AU - Lee, Y.

AU - Dehoff, R. R.

PY - 2018/9/1

Y1 - 2018/9/1

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AB - Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can be used for repair and reclamation of nickel alloy components. The current paper explores opportunities for innovation and qualification challenges with respect to deployment of AM as a disruptive manufacturing technology. In the first part of the paper, fundamental correlations of processing parameters to defect tendency and microstructure evolution will be explored using DED process. In the second part of the paper, opportunities for innovation in terms of site-specific control of microstructure during processing will be discussed. In the third part of the paper, challenges in qualification of AM parts for service will be discussed and potential methods to alleviate these issues through in situ process monitoring, and big data analytics are proposed.

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Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

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