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ADDITIVE MANUFACTURINGSECTION TITLE


hot sections of engines are usually some of the most expensive, and due to the harsh environment in which they work, have short life-cycles. Using the L-PBF process with high-temperature alloys offers manufacturers the opportunity to benefit from better inventory management, reducing late penalties due to tooling delays, and creating more intricate shapes, often allowing the integration of several components in a sub-assembly into one. It was to address this requirement that


Alloyed worked with leading aerospace OEM Honeywell to test a new high- temperature nickel alloy, ABD 900AM, with the L-PBF process, to determine if it could serve as a replacement for existing high temperature casting alloys. Te purpose of this effort was to discover at a high level if ABD 900AM showed promise and warranted further development. After an initial introduction to Alloyed


by a third party, Honeywell recognised the potential of the Alloys By Design (ABD) system brand developed by highly respected metallurgists from Oxford University and this stimulated further interest in the ABD-900AM material and its potential for high-temperature aerospace applications as it was not prone to cracking. Te result of this initial collaboration was a dedicated project that would see Honeywell build a limited number of test specimens in its additive manufacturing laboratory located in Bangalore, India. Honeywell would build and test the material to determine if the results merited continued investment and development. ABD-900AM is an age-hardenable, nickel-based superalloy designed specifically for use as feedstock in the L-PBF process. It is optimised for environmental resistance and high- temperature tensile strength, with a working temperature range up to 900°C in its age-hardened state. It not only offers a higher operating temperature but also significant long term stability. Exhibiting excellent creep strength, the material has also demonstrated superior resistance to cracking during manufacture and heat treatment, enabling complex part design. It is designed to be free of solidification, liquidation and strain-age cracks, and showcases exceptional printability for a 40% γ’-phase strengthened alloy. Te alloy also shows high as-printed part density of >99.9%.


Cooling channels created using a metal AM process


TEST RESULTS


Te scope of the collaborative project between Alloyed and Honeywell was the assessment/qualification of the ABD- 900AM Ni-alloy powder for the next generation of additively manufactured high temperature applications. Honeywell has undertaken a series of tests to confirm and optimise the properties of the alloy with some extremely positive results. From a broad perspective, the project


provided a manufacturing assessment and a mechanical property assessment of the alloy.


MANUFACTURING ASSESSMENT Additive manufacturability. It was important to assess how the alloy behaved when processed on a L-PBF machine, and whether the welding operation involved – with all this implies in terms of rapid thermal gradients – would deleteriously effect the integrity of the final part. Various test geometries were trialled on an EOS metal system, and component scale testing was undertaken. It was found that there was no part distortion on cracking in the “as- printed” condition, there was good surface finish, and a wide processing window. Powder recyclability. Te ability to be


able to re-use unsintered material from build-to-build is obviously an important factor when looking at the economics of using metal AM processes. Because of this, it was decided to manufacture and test parts made with “used” powder, and it was found that there was no significant


change of properties in the parts made with used powder compared with virgin ABD- 900AM powder. Post processability. It is often the case


that parts must undergo a variety of post-processing activities after the AM build, which can affect the mechanical properties of the material and therefore, the functionality of the part. To assess how the alloy behaved parts were subjected to vacuum heat treatment and hot isostatic pressing (HIP) often used on metal AM parts to eliminate internal voids. Tere was no “post-weld” cracking detected on parts made from the alloy.


SUMMARY Te results of the work between Alloyed and Honeywell show that ABD-900AM is an alloy that demonstrates great potential for high temperature applications. Te material welds and fuses extremely well, particularly when compared with other high temperature nickel alloys. Although it is not a replacement for CM Mar-247 in most cases due to the oxidation capabilities, it does exhibit very good mechanical properties at high temperatures when compared with Mar 247 or IN792 or IN713 or IN738.


Will Dick-Cleland is with the process technology team at Alloyed. www.alloyed.com


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