Additively Manufactured ODS Alloys With Reduced Coarsening and Slag
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Solution Overview
Problem
Conventional manufacturing processes for oxide dispersion-strengthened (ODS) alloys are limited to simple geometries, leading to material waste and increased costs when forming components with complex geometries, and melt-based additive manufacturing attempts result in coarsening and slag formation, degrading alloy properties.
Innovation Solution
Development of ODS alloys compatible with melt-based additive manufacturing, such as laser powder bed fusion, with adjusted compositions and process parameters to reduce coarsening and slag formation, allowing for the fabrication of complex components with maintained properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solid-state powder processing is used to form ODS alloys, then the alloy properties are maintained (reduced oxide agglomeration and coarsening), but the component geometry is limited to simple shapes requiring additional manufacturing steps
Solution Approach 1:
The patent changes the manufacturing process parameter from solid-state powder processing to melt-based additive manufacturing, enabling complex geometries while maintaining alloy properties through controlled melting and rapid solidification that prevents oxide agglomeration and coarsening
Solution Approach 2:
The patent replaces the mechanical solid-state processing system with a thermal melt-based additive manufacturing system, allowing near-net shape fabrication of complex components while maintaining ODS alloy properties through controlled thermal processing
2Device complexity
If melt-based additive manufacturing is used to form ODS alloys, then complex geometries are achieved, but extensive coarsening and slag formation occur degrading alloy properties
Solution Approach 1:
The patent optimizes melt-based additive manufacturing parameters including laser power, scan speed, and hatch spacing to control the thermal field and prevent oxide coarsening and slag formation while enabling complex geometry fabrication
Solution Approach 2:
The patent introduces an intermediary protective atmosphere or controlled environment during the melt-based additive manufacturing process to prevent oxide aggregation and coarsening, allowing complex geometries to be formed while maintaining alloy properties
3Loss of substance
If conventional manufacturing processes are used for ODS alloys, then material waste is reduced, but additional manufacturing steps are required for complex geometries increasing costs
Solution Approach 1:
The patent replaces conventional sequential manufacturing steps with a single melt-based additive manufacturing process that directly fabricates complex geometries, eliminating the need for separate forming and finishing operations while reducing material waste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The ODS alloys and manufacturing processes enable the production of components with reduced coarsening and slag formation, preserving exceptional properties and enabling the fabrication of complex geometries suitable for high-pressure oxygen environments.
Implementation Method 1
melt-based additive manufacturing (AM) processes
Implementation Method 2
additive manufacturing processes for manufacturing components from the ODS alloys disclosed herein
Implementation Method 3
oxide dispersion-strengthened (ODS) alloys exhibit exceptional resistance to frictional ignition due to the presence of oxide nanoparticles, which strengthen the underlying metal
Implementation Method 4
improve the adhesion of a protective oxide tribolayer
Data Source
AI summary
An oxyide dispersion-strengthened (ODS) alloy is disclosed that is compatible with melt-based additive manufacturing processes, such as laser powder bed fusion (L-PBF) while achieving material properties, such as resistance to frictional ignition, comparable to or better than wrought ODS alloys. This is accomplished, in part, by adjusting the composition of the ODS alloy and/or adjusting the operating parameters of the additive manufacturing process to reduce or, in some instances, mitigate dispersoid coarsening and slag formation. For example, a nickel (Ni)-based ODS alloy may include less than 0.3 wt % aluminum (Al) to reduce the formation of low melting point oxides that are prone to coarsening and slag formation. In another example, various processing parameters associated with a selective laser melting process, such as beam power, beam spot size, and scan speed, may be chosen to reduce a melt time associated with the additive manufacturing process.