SBIR Phase I: Advanced Manufacturing of Oxide Dispersion-Strengthened Superalloys for High Temperature Creep and Hydrogen Environment Applications

SBIR 第一阶段：用于高温蠕变和氢环境应用的氧化物弥散强化高温合金的先进制造

• 批准号: 2335531
• 负责人: Joseph Carazzone
• 金额: $ 27.5万
• 依托单位: TOP GRAIN TECHNOLOGIES, INC.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2024
• 资助国家: 美国
• 起止时间: 2024-02-15 至 2025-01-31
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2335531&HistoricalAwards=false
• 关键词: SBIR; Phase; Advanced; Manufacturing; Oxide

The broader impact of this Small Business Innovation Research Phase I project is to advance the conversion of gas turbines for power generation to utilize sustainable hydrogen as a fuel. Although hydrogen offers zero exhaust emissions, it poses challenges due to its higher flame temperature and reactivity with alloys compared to natural gas. This project focuses on developing a high-temperature alloy system, fabricated through additive manufacturing, ensuring longevity and reliability in hydrogen combustion environments. Through scaling a patent-pending thermal treatment, the project aims to enhance the alloy's material properties for durable aftermarket parts like vanes, blades, shrouds, and panel segments. These components can surpass the properties of existing precision investment castings and are essential for converting industrial gas turbines to efficiently burn hydrogen, currently powering a significant portion of US combined heat and power and global electricity generation. The carbon abatement potential is substantial, with the conversion of one targeted segment capable of reducing over 1 GT of CO2 emissions. The innovation extends to manufacturing advanced, high-value components for aerospace jet engine repair and overhaul, presenting a potential Year 3 production revenue of $20 million and providing critical supply base resiliency for hard-to-source components in gas turbines. This Small Business Innovation Research Phase I project aims to advance additively manufactured, high-temperature alloy research, focusing on applications in hydrogen combustion within industrial gas turbines. The project will fabricate mechanical and environmental test specimens using an alloy composition containing oxide dispersion-strengthening constituents designed specifically to withstand reactive hydrogen conditions. Testing will encompass critical properties like creep resistance, low cycle fatigue, and hydrogen embrittlement. A pivotal aspect involves post-processing the alloy through directional heat treatment and modifying the grain structure to enhance creep resistance, which is critical in the high-temperature operation of vane segments, shrouds, blades, and gas turbine components. Studies show superior properties compared to existing additively manufactured superalloys and precision investment cast equivalents. The project's objectives include optimizing the alloy, refining manufacturing conditions, and obtaining key performance data for service conditions. Preliminary design curve data will be established, facilitating the fabrication of components for hot-fire testing and retrofitting into real gas turbine engines. This initiative promises significant progress in high-temperature alloy capabilities, particularly for advancing hydrogen combustion technology in industrial gas turbines.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.

该小企业创新研究第一阶段项目的更广泛影响是推动燃气轮机发电的转换，以利用可持续的氢作为燃料。尽管氢气可以实现零废气排放，但与天然气相比，它具有更高的火焰温度和与合金的反应性，因此带来了挑战。该项目重点开发通过增材制造制造的高温合金系统，确保在氢气燃烧环境中的使用寿命和可靠性。通过扩大正在申请专利的热处理，该项目旨在增强合金的材料性能，以用于耐用的售后零件，如静叶、叶片、护罩和面板部分。这些部件的性能超越了现有精密熔模铸件，对于改造工业燃气轮机以高效燃烧氢气至关重要，目前氢气为美国热电联产和全球发电的很大一部分提供动力。碳减排潜力巨大，一个目标细分市场的转换能够减少超过 1 GT 的二氧化碳排放量。这项创新延伸到制造用于航空航天喷气发动机维修和大修的先进高价值部件，预计第 3 年的生产收入将达到 2000 万美元，并为燃气轮机中难以采购的部件提供关键的供应基础弹性。该小型企业创新研究第一阶段项目旨在推进增材制造的高温合金研究，重点关注工业燃气轮机中氢气燃烧的应用。该项目将使用含有氧化物弥散强化成分的合金组合物制造机械和环境测试样本，该合金组合物专门设计用于承受活性氢条件。测试将涵盖抗蠕变性、低循环疲劳和氢脆等关键性能。一个关键方面涉及通过定向热处理对合金进行后处理，并改变晶粒结构以增强抗蠕变性，这对于静叶段、护罩、叶片和燃气轮机部件的高温运行至关重要。研究表明，与现有的增材制造高温合金和精密熔模铸造合金相比，具有更优越的性能。该项目的目标包括优化合金、改进制造条件以及获取使用条件的关键性能数据。将建立初步设计曲线数据，促进用于热火测试的部件的制造以及改装成真正的燃气涡轮发动机。该倡议有望在高温合金能力方面取得重大进展，特别是在推进工业燃气轮机中的氢燃烧技术方面。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力价值和更广泛的影响审查标准进行评估，被认为值得支持。