US 3D prints crack-free alloy with 2,400°F resistance to build tough turbine engines

Researchers have made significant efforts to enable additively manufactured turbine blades to better handle extreme temperatures. They have developed and 3D printed the lightest crack-free alloy capable of operating without melting at temperatures above 2,400 degrees Fahrenheit.

The milestone was achieved by researchers at Oak Ridge National Laboratory (ORNL) and the National Energy Technology Laboratory (NETL).

The alloy is expected to enable additively manufactured turbine blades to effectively handle extreme temperatures and reduce the carbon footprint of gas turbine engines such as those used in airplanes.

High melting temperature and low density

ORNL’s Saket Thapliyal stated that no one has been able to develop and print alloys with such a high melting temperature and low density without cracks before.

Thapliyal highlighted that while metals such as tungsten can take the heat, they would add too much weight to an airplane.

“This is significant. We’re making something lighter that can hold its structural integrity at ultra-high temperatures,” added Thapliyal.

Two years back, researchers at ORNL had demonstrated a new class of superalloys made of cobalt and nickel that was crack-free and defect-resistant in extreme heat. It was also conducive for use in metal-based 3D printing applications.

At that time, researchers processed the cobalt and nickel class of superalloys and proved that they remained crack-free in electron-beam and laser-melting 3D printing processes.

Researchers also claimed that these metal materials were proven to be cost-effective for manufacturing, and deploying them for use in additive processes could enable the production of innovative, complex designs with minimal material waste .

Latest crack-free alloy is more efficient

The latest crack-free alloy, however, is more efficient than the one previously developed.

The latest significant advancement combines seven elements in a niobium-rich, complex concentrated alloy whose melting point is at least 48% higher than superalloys of nickel and cobalt previously developed at ORNL, according to a press release .

Researchers fine-tuned the electron beam melting process to print test parts for the novel alloy, according to ORNL.

3D printer at ORNL’s Manufacturing Demonstration Facility was used

A 3D printer at the ORNL’s Manufacturing Demonstration Facility was used to print the unusual crack-free alloy.

Previously, it has been a major challenge to produce alloys that don’t crack in extreme heat.

Researchers had claimed that the earlier developed alloy also had material properties necessary for challenging environments because they not only successfully withstood the heat but also retained strength when stretched.

ORNL, which is the world’s premier research institution, teamed with the National Energy Technology Laboratory almost a year ago to jointly explore a range of technology innovations for carbon management and strategies for economic development and sustainable energy transitions in the Appalachian region.

The two labs agreed to develop modern technologies, including clean advanced manufacturing technologies with emphasis on those that can enable the decarbonization of the energy, industrial, transportation and buildings sectors.

Both institutions also conduct research, development, demonstration, and commercialization of sustainable technologies for production, extraction, separation and use of critical minerals, to ensure long-term secure and sustainable domestic supply chains.