Periodic Reporting for period 2 - topAM (Tailoring ODS materials processing routes for additive manufacturing of high temperature devices for aggressive environments)
Periodo di rendicontazione: 2022-07-01 al 2023-12-31
Europe’s industrial sector grapples with multifaceted challenges, notably intensified global competition and the imperative shift towards energy and resource optimization. In response to these pressing demands, topAM undertakes the development and deployment of innovative processing methodologies for next-generation oxide-dispersoid strengthened (ODS) alloys, centered on FeCrAl, Ni, and NiCu substrates. These pioneering ODS materials confer a distinct advantage to the processing industry, facilitating the fabrication of cutting-edge, topology-optimized, sensor-integrated high-temperature devices—such as gas burner heads and heat exchangers—tailored for extreme operational environments. The initiative prioritizes alloy and process refinement through an advanced integrated computational materials engineering (ICME) paradigm, seamlessly integrating computational thermodynamics, microstructure modeling, and process simulation. By leveraging this approach, substantial time and raw material savings are anticipated, alongside enhanced longevity of components. This computational-experimental synergy will be reinforced by extensive materials characterization and rigorous component testing under industrially relevant conditions. Such a comprehensive strategy promises profound insights into the intricate interplay between processing dynamics, microstructural evolution, and material properties, enabling quantification of performance enhancements and lifecycle assessment. Ultimately, this concerted effort aims to drive down costs, elevate energy efficiency, and augment component durability, thereby fortifying Europe’s competitive edge in the domain of additive manufacturing (AM) intertwined with ICME. The consortium, comprising leading industry users, materials suppliers, and research institutions, stands poised to achieve higher competitiveness of materials processing, positioning European SMEs strategically within the value chain and consolidating Europe's prominence in this transformative technological frontier.
Initially, a cross-disciplinary Integrated Computational Materials Engineering (ICME) methodology was implemented to facilitate the physics-based understanding of process-structure-property relationships within ODS alloy systems. Guided by this framework, novel alloy design strategies were developed for both ex-situ and in-situ powder modification methods. The incorporation of nanoparticles was successfully achieved across all techniques, each presenting its own merits and limitations. Notably, in-situ methods like Gas Atomization Reaction Synthesis (GARS) and Post internal nitridation (PIN) demonstrated exceptional efficacy in nanoparticle formation, albeit with extreme speeds. Manipulating oxygen/nitrogen contents in the atomization gas allowed precise control over nanoparticle volume fractions. Particularly advantageous was the streamlined single-step process of in-situ methods, offering fine nanoparticles in printed parts with minimal surface quality alteration of powders. On the other hand, ex-situ techniques facilitated the incorporation of up to 2 vol.-% nanoparticles, yielding highly dense parts with uniform nanoparticle distribution, thereby enhancing properties. The modified alloys underwent rigorous characterization employing a 4-stage control mechanism, culminating in go/no-go decisions based on powder properties, printability, structure, and short-scale testing. Three modifications per alloy with exceptional high-temperature properties were qualified, informed by comprehensive datasheets encompassing powder morphology, optical density, spread ability, and mechanical properties such as tensile and creep behavior. Notably, creep strain rate decreased tenfold, and creep life increased by 500% compared to the base alloy, critical for applications like gas burner heads. Thus, the concepts for new ODS materials produced and processed via novel techniques were established and validated successfully. Furthermore, components were designed using Multiphysics optimization tools, integrating continuous and discrete adjoint methods alongside Fiber Bragg Grating (FBG) sensors, enabling real-time evaluation of material properties during operation. Successful integration of FBG sensors, coupled with real-time data acquisition interfaces, facilitated comprehension of temperature evolution even at high temperatures during operation. The developed AM process parameter exhibited excelled transferability for the heat exchanger components printed using nanoparticle-containing powder of NiCu-based Alloy 400 alongside larger parts using modified Ni-based Alloy 699XA.
In the pursuit of its overarching impact goals, including a 30% improvement in energy efficiency, a 20% reduction in CO2 emissions and resource utilization, and a 20% increase in equipment lifetime, topAM has made significant strides during the 36 months of the project. Leveraging the Integrated Computational Materials Engineering (ICME) framework, meticulous selection of nanoparticles (oxides/nitrides) has been undertaken to enhance material properties, consequently extending equipment lifetimes and yielding substantial CO2 savings. Fundamentals for printing ODS-containing alloys have been established. Moreover, a bolstered competitiveness for SME partners has been attained through strategic positioning within the materials processing value chain. Advancements in gas atomization processes, including the development of parameters for gas atomization of ODS alloys and in-situ internal oxidation/nitridation, underscore the project's technical prowess. Thorough characterization of standard alloy systems has not only confirmed the impact of additive manufacturing (AM) on material properties but also furnished valuable insights for chemical and processing industries seeking AM solutions for high-temperature and corrosive environments. Integration of Fiber Bragg Gratings (FBG) sensors into component design enables continuous performance monitoring, even at temperatures as high as 1000 °C, surpassing the limitations of point-based sensors. This promises enhanced assessment during service and positively impacts resource utilization during maintenance and plant downtime. Through the tailored optimization of alloy compositions, processing parameters, and component geometry, novel alloys are poised to exhibit heightened corrosion resistance, mechanical strength, and operational efficiency, consequently prolonging component lifetimes and expanding operational temperature ranges. Dissemination efforts have been robust, encompassing participation in conferences, trade fairs, peer-reviewed research journals, and patent filings, reflecting the project's commitment to sharing breakthroughs and fostering collaboration within the scientific and industrial communities. Collaborative endeavors within consortia such as the CEM-WAVE cluster and joint symposiums further facilitate knowledge exchange and dissemination of topAM's outcomes, ensuring broad impact and visibility. Communication strategies span various channels, including press releases, websites, social media platforms, briefings, meetings, and specialized project schools, maximizing outreach and engagement with diverse stakeholders.