Alternative Additive Manufacturing to Produce Fossil Energy Critical Systems

Fossil fuels FE) are projected to remain the mainstay of energy consumption and energy generation well into the next century. New technologies including advanced material manufacturing must be developed to promote the efficient environmentally sound use of Americas abundant fossil fuels FE). Additive manufacturing AM) has the potential to reduce manufacturing cost and produce materials that enable power systems to operate with increase efficiencies when FEs are converted to energy with reduced pollution and cost. Friction stir additive manufacturing FSAM) stands apart from other AM for producing welds and near/net shapes free of porosity/defects in the finished part, higher mechanical properties including high resistance to creep derived from fine equiaxed homogenous microstructure, and superior fatigue properties. FSAM is in contrast to fusion AM processes that have a cast microstructure that is isotropic, highly stressed with pores/defects. In a team effort with the world renowned Professor Rajiv Mishra at the University North Texas UNT) this program will investigate the high- temperature steel alloy T/P92 9Cr-2W-Mo-V-Nb-N) utilizing FSAM for application in ultra- supercritical USC) power plants. The 92 steel alloy will be joined with FSW and produced in near/net 3D shape via FSAM. Complete characterization of the FSAM produced 92 steel alloy will be performed to demonstrate the superior properties and lower cost achievable with FSAM processing. Fossil Energy FE) will continue to play a critical role in energy generation but requires advanced materials at reduced manufacturing cost while reducing emissions. Conventional substrative manufacturing and fusion welding of steels limit advancements in FE utilization, pollution control and reducing cost. Additive manufacturing AM) offers the potential to reduce manufacturing cost via producing and welding advanced materials with superior properties. Friction stir welding and as additive manufacturing FSAM) in contrast to fusion welding and fusion AM) produces an equiaxed anisotropy defect/pore free microstructure in welds and 3D produced near/net shaped parts with enhanced mechanical properties. FSAM will be utilized to optimize T/P 92-grade steel as welds and produced as 3D near/net shape parts with complete characterization for FE applications. In addition to FSAM producing wide varieties of 3D near/net shape parts and welds in 92-grade steel for FE applications, other steels can be FSAM produced for FE applications as well as other steel alloys and virtually any metal alloy for applications in general industry/ commercial , defense, aerospace, automotive and consumer industries.