Tailoring ODS materials processing routes for additive manufacturing of high temperature devices for aggressive environments

Project Information

topAM

Grant agreement ID: 958192

DOI

10.3030/958192

Project closed

EC signature date 3 December 2020

Start date 1 January 2021

End date 31 December 2024

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Advanced manufacturing and processing

Total cost

€ 5 999 645,00

EU contribution

€ 5 999 645,00

Coordinated by

RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHEN
Germany

Periodic Reporting for period 3 - topAM (Tailoring ODS materials processing routes for additive manufacturing of high temperature devices for aggressive environments)

Reporting period: 2024-01-01 to 2024-12-31

Summary of the context and overall objectives of the project

The project topAM focussed on addressing the challenges faced by European industries due to global competition and the need for energy and resource efficiency. Specifically, we developed and implemented novel oxide-dispersoid strengthened (ODS) alloys based on NiCrAl-Superalloys (Alloy 699/602) and NiCu Alloy 400 using additive manufacturing (AM) for high-temperature devices exposed to aggressive environments. These new materials will enhance the durability and performance in applications, such as gas burner heads and heat exchangers. The development of these advanced materials and manufacturing techniques is crucial for society. This contributes to increasing energy and resource efficiency, which is vital for industrial sustainability, and enabling the production of high-performance components with superior mechanical properties, thereby reducing waste and enhancing the lifespan of industrial equipment. It supports Europe's technological leadership in additive manufacturing (AM) and material science, strengthening industrial competitiveness. The project has promoted cost reduction, improved energy efficiency, and environmental benefits by developing materials that last longer and function better under extreme conditions. The main objectives achieved were developing and optimizing new ODS alloys tailored for laser-beam powder bed fusion (PBF-LB/M) additive manufacturing. Using Integrated Computational Materials Engineering (ICME) that combines computational thermodynamics, microstructure modeling, and process simulation, the efficiency of alloy design and processing was enhanced. Manufacturing high-temperature components, such as topology-optimized and sensor-integrated gas burner heads and heat exchangers were performed and their comprehensive testing and characterization of the novel materials for their microstructure, mechanical properties and life cycle assessment were conducted to evaluate their performance under real-world industrial conditions.
topAM strengthens Europe’s position in advanced materials and additive manufacturing through collaboration between leading research institutes, SMEs, and industrial partners.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The topAM project successfully implemented a cross-disciplinary Integrated Computational Materials Engineering (ICME) methodology to establish a physics-based understanding of process-structure-property (PSP) relationships in Oxide Dispersion Strengthened (ODS) alloys. This approach facilitated the design and optimization of novel Ni- and NiCu-based ODS alloys ODS alloys, leveraging both ex-situ and in-situ powder modification techniques. In-situ techniques, such as Gas Atomization Reaction Synthesis (GARS) and Post Internal Nitridation (PIN), demonstrated exceptional nanoparticle formation efficiency, with precise control over volume fraction by adjusting oxygen/nitrogen levels during atomization. These methods allowed for single-step processing, ensuring a fine dispersion of nanoparticles in printed parts with minimal alteration to powder surface quality. Conversely, ex-situ techniques enabled the incorporation of up to 2 vol.-% nanoparticles, yielding highly dense components with uniform particle distribution, thereby enhancing mechanical and thermal properties. A rigorous four-stage control mechanism was applied to validate powder properties, printability, microstructural integrity, and mechanical performance through short-scale testing. The results confirmed that creep strain rate decreased tenfold, while creep life improved by 500% compared to base alloys -critical for applications such as gas burner heads. Furthermore, multiphysics optimization tools integrating adjoint methods and Fiber Bragg Grating (FBG) sensors enabled real-time material property monitoring during high-temperature operation. The AM process parameters developed within the project exhibited high transferability, facilitating successful PBF-LB/M fabrication of heat exchanger components using nanoparticle-enhanced NiCu-based Alloy400 and Ni-based Alloy 602 and 699XA for larger parts. A signficant material database was generated for all the developed alloys. These advancements significantly improve energy efficiency, extend component lifetimes, and enhance sustainability, with a breakthrough in high-performance industrial applications.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The project topAM has successfully advanced the development of Ni- and NiCu-based ODS alloys, specifically designed for high creep resistance, corrosion resistance, and superior mechanical durability in extreme environments. Through nano-sized oxide and nitride integration, these alloys exhibit significantly improved strength, oxidation resistance, and longevity. The implementation of ICME approach has enhanced the efficiency of alloy design, leading to a 500% increase in creep life, a tenfold reduction in creep strain rate, and an increase in service temperature by 50°C, demonstrating the high performance potential of these materials in demanding industrial applications. Laser-Beam Powder Bed Fusion (PBF-LB/M) process parameters were optimized to ensure defect-free printing of ODS alloys, achieving high mechanical integrity and density. Advances in powder atomization resulted in a 99% powder recycling rate, significantly reducing material waste and enhancing cost-effectiveness. The project also developed topology-optimized gas burner heads and heat exchangers equipped with integrated Fiber Bragg Grating (FBG) sensors, allowing real-time monitoring of material degradation and operational performance. These efforts led to a 32°C reduction in operational temperatures, improving thermal efficiency and reducing NOx emissions. The Life Cycle Assessment (LCA) analysis confirmed a 21% reduction in CO2 emissions compared to conventional manufacturing. Additionally, energy efficiency improvements of at least 30% were achieved by optimizing the processing chain and increasing service temperature, while reducing joining steps and improving fuel usage. These developments contribute to more sustainable and cost-effective manufacturing practices, particularly for industries relying on high-temperature operations.
The project topAM validated the new ODS alloys through full-scale industrial testing, ensuring their performance under extreme conditions. The technology transfer and commercialization strategy includes one patent application, preparation of business cases, and market studies to enable industrial adoption. Dissemination efforts included conferences, trade fairs, peer-reviewed research journals, reflecting the project's commitment to collaborating with scientific and industrial communities. Furthermore, collaborative engagements, such as those with the CEM-WAVE cluster, have strengthened the dissemination of topAM’s innovations and expanded their impact across various high-temperature applications.

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