The project topAM has successfully advanced the development of Ni- and NiCu-based ODS alloys, specifically designed for high creep resistance, corrosion resistance, and superior mechanical durability in extreme environments. Through nano-sized oxide and nitride integration, these alloys exhibit significantly improved strength, oxidation resistance, and longevity. The implementation of ICME approach has enhanced the efficiency of alloy design, leading to a 500% increase in creep life, a tenfold reduction in creep strain rate, and an increase in service temperature by 50°C, demonstrating the high performance potential of these materials in demanding industrial applications. Laser-Beam Powder Bed Fusion (PBF-LB/M) process parameters were optimized to ensure defect-free printing of ODS alloys, achieving high mechanical integrity and density. Advances in powder atomization resulted in a 99% powder recycling rate, significantly reducing material waste and enhancing cost-effectiveness. The project also developed topology-optimized gas burner heads and heat exchangers equipped with integrated Fiber Bragg Grating (FBG) sensors, allowing real-time monitoring of material degradation and operational performance. These efforts led to a 32°C reduction in operational temperatures, improving thermal efficiency and reducing NOx emissions. The Life Cycle Assessment (LCA) analysis confirmed a 21% reduction in CO2 emissions compared to conventional manufacturing. Additionally, energy efficiency improvements of at least 30% were achieved by optimizing the processing chain and increasing service temperature, while reducing joining steps and improving fuel usage. These developments contribute to more sustainable and cost-effective manufacturing practices, particularly for industries relying on high-temperature operations.
The project topAM validated the new ODS alloys through full-scale industrial testing, ensuring their performance under extreme conditions. The technology transfer and commercialization strategy includes one patent application, preparation of business cases, and market studies to enable industrial adoption. Dissemination efforts included conferences, trade fairs, peer-reviewed research journals, reflecting the project's commitment to collaborating with scientific and industrial communities. Furthermore, collaborative engagements, such as those with the CEM-WAVE cluster, have strengthened the dissemination of topAM’s innovations and expanded their impact across various high-temperature applications.
