Accelerating Alloy Development for Additive Manufacturing

Kammermeier E, Weidinger J, Ionov I, Ramsperger M, Wahlmann B, Körner C, Zenk C (2024)

Publication Type: Conference contribution

Publication year: 2024

Publisher: Springer Science and Business Media Deutschland GmbH

Pages Range: 116-127

Conference Proceedings Title: Minerals, Metals and Materials Series

Event location: Pennsylvania, PA

ISBN: 9783031639364

DOI: 10.1007/978-3-031-63937-1_11

Abstract

Additive manufacturing (AM) is revolutionizing the production of complex superalloy parts, yet its advancement is hindered by the high costs and extensive time required for atomizing powders from which new alloys are produced and tested. This study presents our approach to expedite and economize alloy development for AM. At the heart of this method is the CALPHAD calculation of phase Diagrams (CALPHAD)-based multi-criteria optimization algorithm PyMultOpt, utilized for selecting potential alloys, which are then produced through arc-melting. Our innovative testing framework involves two key processes: (i) assessing alloy processability via electron beam remelting of bulk material, and (ii) evaluating mechanical properties after refining coarse-grained material via deformation and recrystallization. Focusing on Alloy 247 and derivatives selected through PyMultOpt, our approach successfully emulates AM-like microstructures in arc-melted material. The compressive creep tests on the recrystallized microstructure of Alloy 247 indicate a minimal creep rate comparable to that of AM specimens. Moreover, profilometry-based indentation plastometry tests at 760 °C offer a rapid, high-temperature evaluation method, allowing for preliminary alloy ranking before extensive creep testing. This study demonstrates that remelting and recrystallization of bulk material can reproduce AM-like microstructures, enabling a faster and more cost-effective assessment and ranking of new alloys in terms of their mechanical properties and AM-processability, as opposed to the traditional, powder-dependent alloy development methods.

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How to cite

APA:

Kammermeier, E., Weidinger, J., Ionov, I., Ramsperger, M., Wahlmann, B., Körner, C., & Zenk, C. (2024). Accelerating Alloy Development for Additive Manufacturing. In Jonathan Cormier, Ian Edmonds, Stephane Forsik, Paraskevas Kontis, Corey O’Connell, Timothy Smith, Akane Suzuki, Sammy Tin, Jian Zhang (Eds.), Minerals, Metals and Materials Series (pp. 116-127). Pennsylvania, PA, US: Springer Science and Business Media Deutschland GmbH.

MLA:

Kammermeier, Elisabeth, et al. "Accelerating Alloy Development for Additive Manufacturing." Proceedings of the 15th International Symposium on Superalloys, ISS 2024, Pennsylvania, PA Ed. Jonathan Cormier, Ian Edmonds, Stephane Forsik, Paraskevas Kontis, Corey O’Connell, Timothy Smith, Akane Suzuki, Sammy Tin, Jian Zhang, Springer Science and Business Media Deutschland GmbH, 2024. 116-127.

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