Additive Manufacturing of ODS Machine Components for Creep Resistance
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Solution Overview
Problem
Current manufacturing processes for high-temperature machine components, such as turbomachine components, are expensive and inflexible, particularly when using Oxide Dispersion Strengthened (ODS) superalloys, and existing additive manufacturing methods lack guidance on introducing oxides into superalloy powders for enhanced creep resistance.
Innovation Solution
A method involving a powder blend of metal-containing materials and strengthening dispersors, like ceramic oxides, is used in additive manufacturing to create turbomachine components, where the dispersors are finely distributed to enhance high-temperature creep resistance without increasing fragility, utilizing techniques like electron beam melting or direct metal laser melting under controlled atmospheres.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sintering processes are used to manufacture components from ODS superalloy powder, then components can be produced, but the manufacturing process becomes expensive and non-flexible
Solution Approach 1:
The patent changes the manufacturing process parameters by transitioning from sintering to additive manufacturing (Laser Metal Deposition, Electron Beam Melting). This parameter change enables complex geometry production, reduces material waste, eliminates mold requirements, and improves manufacturing flexibility while maintaining component reliability from ODS superalloy powder
Solution Approach 2:
The patent replaces the mechanical sintering process with energy-based additive manufacturing processes (laser or electron beam). This substitution eliminates the need for physical molds and enables direct digital manufacturing of complex geometries, resolving the contradiction between production capability and manufacturing flexibility
2Productivity
If conventional superalloy powder is used in additive manufacturing, then components can be manufactured, but high-temperature creep resistance is insufficient
Solution Approach 1:
The patent creates a composite material system by dispersing oxide particles (Al2O3, Y2O3, TiO2, etc.) within the superalloy matrix during additive manufacturing. This composite approach provides both the manufacturing efficiency of additive processes and the high-temperature creep resistance of ODS superalloys, resolving the contradiction between productivity and reliability
Solution Approach 2:
The oxide dispersors act as intermediaries that transfer the creep resistance property from the powder blend to the manufactured component. These dispersors are introduced during additive manufacturing to enable high-temperature performance while maintaining the productivity benefits of additive processes
3Reliability
If oxide dispersors are added to enhance creep resistance, then high-temperature performance improves, but material complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the oxide dispersor preparation with the additive manufacturing process by pre-mixing oxides with metal powders to create a ready-to-use powder blend. This combining approach simplifies the overall manufacturing system by integrating multiple functions (oxide dispersion, material deposition, and component building) into a single additive manufacturing process
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
This approach enables the production of turbomachine components with improved high-temperature creep resistance and mechanical properties at lower costs, while maintaining component strength and flexibility in design, by carefully controlling grain size distribution and preventing chemical alterations during the manufacturing process.
Implementation Method 1
a first portion of the powder material is locally melted using an energy source, such as but not limited to an electron beam
Implementation Method 2
EP 2586887 discloses processes for manufacturing turbine blades by additive manufacturing, e.g. using Laser Metal forming
Implementation Method 3
Use of Oxide Dispersion Strengthened (ODS) superalloys as suitable materials for manufacturing machine components subject to high temperature fatigue cycles
Data Source
AI summary
A method for manufacturing a machine component made of metal-based material is described. The method comprises the steps of: providing a powder blend comprising at least one metal-containing powder material and at least one strengthening dispersor in powder form, wherein the strengthening dispersor in powder form has an average grain size less than an average grain size of the metal-containing powder material; and forming the machine component by an additive manufacturing process using the powder blend.