Additive manufacturing of Hastelloy X: the effects of the process parameters on the state of the residual stress and material microstructure

哈氏合金X增材制造：工艺参数对残余应力状态和材料微观结构的影响

• 批准号: 542550-2019
• 负责人: Abdolvand, Hamidreza
• 金额: $ 1.82万
• 依托单位: University of Western Ontario
• 依托单位国家: 加拿大
• 项目类别: Engage Grants Program
• 财政年份: 2019
• 资助国家: 加拿大
• 起止时间: 2019-01-01 至 2020-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=680229
• 关键词: Additive; manufacturing; Hastelloy; effects; process

The demand for reducing greenhouse gases has led engineers to design new materials processes that would result in optimized performance. This includes optimizing component geometry to deliver the same task, but efficiently. Additive manufacturing is one of the few manufacturing methods that allows engineers to make components with complex geometries. In this method, the geometry of the component is normally designed in a computer which feeds the geometry data to a hardware that deposit materials layer upon layer.Laser power bed fusion (LPBF) is one of the additive manufacturing techniques that uses laser to melt a thin layer of metal powder that is added upon the previous layer. It is recently employed for manufacturing the nickel-based components of gas turbine. For example, Hastelloy-X is a nickel based superalloy that is used for manufacturing turbine components using LPBF method. Due to significant temperature variation from liquid metal to final solid component, thermal residual stresses develop in the component during LPBF additive manufacturing; this can significantly affect the performance of the final product or their fatigue life. This project will focus on characterizing the state of the residual stresses and materials microstructures as a function of LPBF process parameters. Numerical models have been developed at Siemens that predict the state of the residual stresses in the end-product, but they need validation data. We will use Lab-based X-ray methods to measure surface stresses in Hastelloy-X components. Internal stresses will be measured by the use of neutron and synchrotron X-ray diffraction. Further, the variation of microstructure as function of process parameters will be studied. This is to understand the underlying mechanism that relates Hastelloys-X microstructures to component performance. This information will be used by Siemens to further advance the efficient manufacturing of turbine components.

减少温室气体的需求导致工程师设计新的材料工艺，从而导致优化性能。这包括优化组件几何以实现相同的任务，但有效。添加剂制造是允许工程师制造具有复杂几何形状的组件的少数制造方法之一。在这种方法中，该组件的几何形状通常在计算机中设计，该计算机将几何图数据馈送到硬件上，该硬件将材料放置在层上。laserPower Bed Fusion（LPBF）是使用激光熔化的添加剂制造技术之一，可以融化上一层的金属粉末。它最近用于制造燃气轮机的基于镍的组件。例如，Hastelloy-X是一种基于镍的超合金，用于使用LPBF方法制造涡轮机组件。由于液体金属到最终固体成分的明显变化，在LPBF添加剂制造过程中，组件中会出现热残留应力。这可以显着影响最终产品的性能或其疲劳寿命。该项目将集中于表征残余应力和材料微结构的状态，这是LPBF过程参数的函数。在西门子已经开发了数值模型，该模型预测了最终产品中残留应力的状态，但需要验证数据。我们将使用基于实验室的X射线方法来测量Hastelloy-X组件中的表面应力。内部应力将通过使用中子和同步加速器X射线衍射来衡量。此外，将研究微结构作为过程参数的函数的变化。这是为了了解将Hastelloys-X微结构与组件性能相关联的基本机制。西门子将使用此信息进一步推进涡轮组件的有效制造。