Abstract
Gas turbines feature many components that require superalloys capable of handling extreme thermal environments. Increasing the selection of materials available for these components is important to their use in these extremely high temperature environments. This study investigated two recently developed materials intended to be used for additive manufacturing (AM) with one superalloy based on Cobalt and the other on Nickel. Sets of four test coupons were built using the materials, in addition to the commonly used Inconel-718, on multiple laser powder bed fusion (L-PBF) machines. Several build conditions were varied between coupon sets including coupon orientation, contour settings, and upskin and downskin treatment. Each set of test coupons featured four unique cooling designs to explore how different cooling technologies would be impacted by the variations in build conditions. After being built, coupons were CT scanned to determine accuracy to design intent and quantify the surface roughness. The CT scans indicated that horizontally built test coupons had significantly higher deviation from design intent and higher surface roughness than those built vertically. Results also indicated that the Cobalt-based alloy consistently had a smoother surface quality with lower surface roughness compared to the nickel-based alloy. After geometric characterization, the cooling performance of the test coupons was measured experimentally. Pressure losses were found to correlate with increases in surface roughness; however, in some cases the convective heat transfer did not increase proportionally to the pressure loss as a result of surface features significantly blocking the flow without proportionally increasing convective heat transfer.
| Original language | English |
|---|---|
| Title of host publication | Heat Transfer - General Interest/Additive Manufacturing Impacts on Heat Transfer; Internal Air Systems; Internal Cooling |
| Publisher | American Society of Mechanical Engineers (ASME) |
| ISBN (Electronic) | 9780791887011 |
| DOIs | |
| State | Published - 2023 |
| Event | ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023 - Boston, United States Duration: Jun 26 2023 → Jun 30 2023 |
Publication series
| Name | Proceedings of the ASME Turbo Expo |
|---|---|
| Volume | 7-B |
Conference
| Conference | ASME Turbo Expo 2023: Turbomachinery Technical Conference and Exposition, GT 2023 |
|---|---|
| Country/Territory | United States |
| City | Boston |
| Period | 06/26/23 → 06/30/23 |
Funding
This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the US Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a nonexclusive, 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). Research was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office, under Contract DE-AC05-00OR22725 with UT-Battelle LLC. This work was performed in part at the Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, an Office of Energy Efficiency and Renewable Energy user facility.
