Integrated Process and Materials Modeling for Development of Additive Manufacturing of Refractory Materials for Critical Applications

Nithin Panicker, Bhagyashree Prabhune, Marco Delchini, Nate See, Brian Jordan, Bryan Lim, Soumya Nag, Yuri Plotnikov, Pikee Priya, Yousub Lee

Research output: Book/ReportCommissioned report

Abstract

The research is focused on establishing computational framework, fundamental knowledge, and powder direct energy deposition (DED) capabilities for accelerating the use of refractory metals for gas turbine generation, which is considered a significant enabling technology for increasing operating temperatures and improving efficiency of these system. A computational fluid dynamics (CFD) melt pool simulation for refractory alloy of C103 was developed in Star-CCM+ by incorporating physical interactions among the heat source, material, and manufacturing parameters in multi-physics simulation. The main set of experimental data was obtained from DED trials using C103 powder at the Commonwealth Center for Advanced Manufacturing (CCAM). The modeling results, along with experimental data, were used to establish process maps for defect detection and geometric precision. The outcomes of simulations and data for C103 can be used to optimize the process parameters and tool path strategies to ensure the defect-free parts. The technology developed in the project supports the optimization of the powder DED.
Original languageEnglish
Place of PublicationUnited States
DOIs
StatePublished - Feb 2024

Keywords

  • 36 MATERIALS SCIENCE
  • 97 MATHEMATICS AND COMPUTING

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