5566.002 Proliferation of Nickel Superalloy Material Datasets for Powder Bed Fusion Additive Manufacturing

ABD®900AM superalloy with high-temperature performance that exceeds AM 939 with the printability of Inconel 718.

Problem

The availability of statistical additive manufacturing (AM) material datasets for high-strength nickel alloys is limited and critical to strategic defense applications. This limitation delays the design maturation of new and innovative products that enable tactical advantages. The cost of testing multiple material lots, studying printer variability, and understanding powder reuse effects presents a complex challenge to obtaining reliable material properties and characteristics for use in product design and development. This project closes the data gap with high-strength, high-temperature AM nickel and accelerates new product development for highly engineered critical technology applications.

Objective

This material qualification program establishes a statistically valid dataset for high-strength nickel, ABD®900AM allowables for components manufactured using laser powder bed fusion (LPBF) technology. Qualification is supported by the development of approved powder, material, and reuse specifications which provide the necessary framework for material procurements, design, and analysis; process specifications; and manufacturing implementation. Material property data will be disseminated to America Makes members through Core to proliferate the strategic use of ABD®900AM, ultimately enabling a modernized defense industrial ecosystem.

Technical Approach

Electric Power Research Institute (EPRI) will follow a structured and standardized approach to generate ABD®900AM design allowables using Aerospace Material Specifications (AMS), NASA, and Metallic Materials Properties Development and Standardization (MMPDS) standards. EPRI expects to process test specimens using Renishaw, EOS, and Trumpf printers in establishing design allowables. The technical framework for generating statistical allowables leverages a conservative framework of specifications for powder, material, processing, and heat treatment which are supported by development testing of key process variables with acceptability limits. Certified chemical and mechanical property testing follows specification development and provides the basis for a robust statistical ABD®900AM material dataset. The technical approach includes strong collaboration with an advisory group consisting of industry, government, and regulatory experts to ensure material readiness for commercial and tactical applications requiring high-temperature and strength characteristics.

Project Participants

Project Principal

Other Project Participants

  • America Makes
  • NCDMM
  • Alloyed Limited
  • Boeing
  • Citrine Informatics
  • Product Evaluation Systems
  • Siemens Energy
  • The Barnes Global Advisors

Public Participants

  • U.S. Department of Defense

Project Summary

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