Superalloy MMC Components for Advanced Turbine Systems

Advanced turbine component manufacturing process by conventional processes are comprised of multiple steps, turbine components are machined from a forged or rolled billet originally made from casting/ingot metallurgy. As a result a long lead times are required prior to acquisition. General Statement of how this problem being addressed: Rapid fabrication of this component can be done by Additive Manufacturing (AM) process where parts are fabricated by successive melting of layers of metal powder rather than like a conventional process. By AM each layer is melted to the exact geometry defined by a 3D CAD model. By AM the same part could be fabricated within hours directly from powder. For Phase I grant application what is planned for Phase I? This DOE SBIR Phase I program will develop innovative EBM/DMLS system compatible engineered superalloy powders (high electrical conductivity for EBM and high laser absorptivity for DMLS) for fabrication of porosity free high strength, high fracture toughness, stress corrosion cracking (SCC) resistant structural advanced superalloy (equivalent to IN740) turbine component by additive manufacturing . This program will reduce the time and cost required to get production parts for DOE. Phase II will continue to develop this materials and will fabricate more specific components for DOE applications. Commercial Applications If successful, the rapid fabrication of superalloy component developed by AM in this SBIR program will reduce the cost and enhance the life and performance of current advanced turbine components. Examples of these are rotor/ disc, blade, bolt, superheater tubing and thick sections. The composite powders developed in this program could be used for thermal sprayed or cold sprayed steam oxidation, corrosion resistant high tempererature coatings for retrofitting existing fossil-fired power plant equipment and also applied as laser additives manufacturing for turbine engine/ blade repairing or refurbishing Key Words EBM/DMLS compatible engineered superalloy powder, additive manufacturing, superalloy components, high strength, high temperature resistant, thermal fatigue resistant, advanced turbine system