Additive Manufacturing of Ultrahigh Temperature Refractory Metal Alloys ULTIMATE Kickoff Meeting March 19, 2021 John H. Perepezko, University of Wisconsin-Madison Dan J. Thoma, University of Wisconsin-Madison Laurence D. Marks, Northwestern University Fan Zhang, Computherm LLC Co-PI names, Institutions
Additive Manufacturing of Ultrahigh Temperature Refractory ...
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PowerPoint PresentationJohn H. Perepezko, University of
Wisconsin-Madison Dan J. Thoma, University of Wisconsin-Madison
Laurence D. Marks, Northwestern University Fan Zhang, Computherm
Co-PI names, Institutions
10% efficiency gain .
alloys/elements. This has never been
done in selective laser melting.
Key illustrations, charts, and tables summarizing the
technology development, how the FOA technical
targets will be met, and feasibility.
Proposed Key Targets Metric State of the Art Proposed
Operating temperature 1100°C 1300°C
0.2% tensile yield strength,
Manufacturability $1000/blade 20% reduction
Motivation & Goals of the project
Technical Approach & Innovations of the project
Major milestones, tasks, goals & risks Potential Risks
Use of DED for alloy design and sample fabrication. Use of nitride
for reactive sintering, elemental powders, and impurities may offer
reduced in situ mixing, or porosity, thus affecting chemical
Use of SLM for final specimen manufacture. Pre-blends of powder
reduce in situ mixing and complete reactions leading to porosity,
though porosity is typically not a critical flaw in SLM.
Integrating alloy development with oxidation resistant
characterization and to validate thermodynamic and process
The results from the DED effort will provide essential input to
process parameter prediction for SLM scale-up. A key effort will
to investigate appropriate energy densities and reaction
to effectively translate the processing conditions between the
finalized to control microstructures, defects, and residual
The information will be used to develop a report that
optimized SLM parameters (i.e. scan strategies, beam size,
etc.), heat-treatments (if any) or any other post-processing for
production of Mo-alloy with acceptable microstructure and
mechanical test bars as specified by appropriate ASTM E8 /
method. The largest dimensional variations among the five
must be less than 0.1mm
M7 Finalized T2M
A final T2M plan will be submitted that includes product
requirements, analysis of manufacturing risks, and potential
The development of manufacturing processes for ultrahigh
temperature RMAs for use in gas turbine applications can
be transferred to industrial companies for the processing of RMAs
to manufacture dimensionally controlled shapes such
as a turbine airfoil. The demonstrated use of reactive synthesis of
readily available powder stock instead of alloy powders
results in a significant simplification of the supply chain and a
reduction in feedstock material cost.
The primary market space is identified as AM-based refractory alloy
production of ultra-high temperature, high
performance components for aerospace, power generation, and
military power conversion. The path to these markets is
anticipated to be refractory and superalloy material suppliers,
sub-system suppliers of gas turbine equipment, AM
specialty manufacturers, AM equipment manufacturers, materials
process database providers, materials and power system
research institutes, all of which out team already has strong
The first market application we are targeting is the production of
gas turbine blades capable of operation in
temperature regimes up to 1300oC. It is anticipated that an initial
entry strategy to first commercialization would be the
licensing of design software, databases, and optimized blade
topologies to gas turbine OEMs and/or their supply chains.