SBIR Phase I: Multi-principal element alloy fillers for toughness enhancement in repair of Ni-base superalloy components

SBIR 第一阶段：用于镍基高温合金部件修复中增强韧性的多主元合金填料

• 批准号: 2208777
• 负责人: Benjamin Schneiderman
• 金额: $ 25.6万
• 依托单位: HYSA FILLERS L.L.C.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2022
• 资助国家: 美国
• 起止时间: 2022-09-15 至 2024-02-29
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2208777&HistoricalAwards=false
• 关键词: SBIR; Phase; Multi; principal; element

The broader impact of this SBIR Phase I project will be to improve safety and reliability, and to reduce operating costs, for gas turbine engines, a technology that impacts the daily lives of Americans by providing electric power and aircraft propulsion. Moreover, the national defense and energy industries are particularly reliant upon this technology, making this project highly impactful to these aspects of American welfare. Gas turbine engines contain nickel alloy blades, which must be carefully inspected and repaired at regular intervals to ensure failure never occurs unexpectedly, as in-service failures inevitably result in catastrophic engine damage. The integrity of repairs is largely dependent upon mechanical performance of filler alloys designed to patch cracks and cavities in the engine blades, which this project aims to improve through novel metallurgical design grounded in fundamental science. The scientific community at large will benefit from this research, as it will pioneer applied development for alloys within an emerging material class only two decades in the making. Designed alloys will have a commercial advantage over existing repair products due to superior performance and similar cost. This advantage will form the core of a successful business opportunity, which will generate revenue and provide STEM jobs as the business expands. When designing new alloys from the ground up, rather than making modifications to existing alloys, limitless possibilities arise in multi-principal element alloys regarding which metallic elements to include and in what concentrations, necessitating a careful design strategy to efficiently identify candidates for a particular application. This project employs, as its strong technical innovation, a rigorous alloy selection strategy grounded in fundamental physics-based calculations to achieve this outcome. Equilibrium and non-equilibrium metallurgical thermodynamics calculations form the core of the selection strategy, with the aim to identify alloy compositions in which phases detrimental to mechanical performance are most likely to be suppressed. The project will design and test alloys to address cross-cutting industrial challenges – first and foremost, filling cracks in complex nickel-base superalloys designed for use in the harsh operating environment of a gas turbine engine. Much of the scope of work in this project will involve a vetting process to test whether the filler alloys can withstand these harsh conditions after crack repairs are performed. It will be of critical industrial relevance to validate their long-term metallurgical and mechanical viability in a simulated environment.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

该SBIR I期项目的更广泛的影响是提高安全性和可靠性，并降低燃气轮机发动机的运营成本，该技术通过提供电力和飞机推进来影响美国人的日常生活。此外，国防和能源行业尤其依赖这项技术，这使该项目对美国福利的这些方面产生了重大影响。燃气轮机发动机包含镍合金叶片，必须定期检查和修复，以确保失败永远不会出乎意料，因为在服务中失败不可避免地会造成灾难性的发动机损害。维修的完整性在很大程度上取决于填充合金的机械性能，旨在修补发动机叶片中的裂纹和空腔，该项目旨在通过基于基本科学的新型冶金设计来改进。整个科学界将从这项研究中受益，因为它将在制造中只有二十年的新兴材料类中的合金开发开发。由于性能卓越和相似的成本，设计合金将比现有维修产品具有商业优势。这一优势将构成成功的商机的核心，随着业务的扩大，该机会将产生收入并提供STEM工作。当从头开始设计新合金，而不是对现有合金进行修改，而是在多授权元素合金中出现了无限的可能性，这些元素是关于要包括哪些金属元素以及哪些浓度（以确定有效识别特定应用程序候选者的仔细设计策略）的浓度所必需的。该项目用作强大的技术创新，是一种基于基本物理学的计算以实现这一结果为基础的严格合金选择策略。平衡和非平衡冶金热力学计算构成了选择策略的核心，目的是识别合金组成，其中最有可能抑制对机械性能有害的相位。该项目将设计和测试合金，以应对横切工业挑战 - 首先，填充了旨在在燃气轮机发动机的Harmsh操作环境中使用的复杂镍基超级合金的裂缝。该项目中的许多工作范围将涉及审查过程，以测试填充合金在进行裂缝维修后是否可以承受这些危险条件。在模拟环境中验证其长期冶金和机械可行性将是至关重要的。该奖项反映了NSF的法定任务，并使用基金会的知识分子优点和更广泛的影响审查标准，通过评估被认为是宝贵的支持。