Chen Changjun of the Yangtze River Delta G60 Laser Alliance noted on October 18 that researchers at Oak Ridge National Laboratory (ORNL) and United States Energy Technology Laboratory (NETL) have successfully developed and 3D printed the lightest and crack-free alloy to date, which can withstand high temperatures above 1315°C without melting. This innovation significantly improves the additive manufacturing of turbine blades, which can withstand higher temperatures and reduce the weight of aircraft and gas turbines.
This new alloy is made up of seven elements and is rich in niobium, creating a complex alloy structure. Its melting point is at least 48% higher than that of nickel-cobalt superalloys previously developed at Oak Ridge National Laboratory. By precisely adjusting the electron beam melting process, the researchers were able to print a test part for the alloy.
According to the 3D printing technology reference, the use of EBM process is the key to achieving crack-free 3D printing of this new alloy. Due to the inherently high-temperature nature of the electron beam fusion process and the high flexibility in terms of electron beam deflection and focusing, the process has proven to be less sensitive to crack formation. Successful electron beam melting of multiple easy-to-crack alloys such as Inconel 738, Rene142 and CMSX-4 has been reported in the literature, and GE Aerospace has used the EBM process to batch 3D print the easy-to-crack TiAl alloy engine blades.
In these cases, the samples produced had very low or no crack densities or were completely defect-free. During the electron beam fusion process, the residual level of residual stresses in the material can be reduced by controlling the heat flow and implementing preheating and heating within each layer. In addition, the flexibility of the electron beam movement makes it possible to adopt advanced melting strategies and to control the shape of the melt pool, its solidification behavior, and the corresponding temperature gradient within the melt pool. As a result, cracking problems can be mitigated while the microstructure can be controlled, resulting in the production of "microcastings" with columnar, directionally solidified, and even single-grain microstructures.
Researchers at Oak Ridge National Laboratory said, "Never before has anyone been able to develop and print such a high-melting, low-density, crack-free alloy. "While metals like tungsten are able to withstand high temperatures, they can add significantly to the weight of an aircraft." This achievement is significant. We're making a lighter material that retains structural integrity at ultra-high temperatures. ”
This development opens up new possibilities for the production of high-performance components for the aviation industry. Additive manufacturing enables the efficient production of complex and precise parts, which reduces both production costs and environmental impact. The use of lightweight, high-temperature resistant materials can help improve the efficiency of gas turbines and reduce their carbon footprint.
United States advances in alloy technology at Oak Ridge National Laboratory and the National Energy Technology Laboratory demonstrate the potential of 3D printing technology to provide customized solutions for demanding industrial applications. With this new alloy, the research team has achieved an important milestone in the development of advanced materials that meet the growing demands of modern technology.
Note: The content of this article is compiled and edited by 3D printing technology reference
Reprinted by Chen Changjun of the Yangtze River Delta G60 Laser Alliance