Session: 18-03 Failure Prediction and Life Assessment I

Paper Number: 128276

128276 - Applying Rapid Qualification to Fatigue Assessment of a Binder Jet Superalloy 

Nickel superalloys are critical materials for propulsion applications. One alloy of great importance to turbine engine propulsion is Mar M 247. With great creep and oxidation resistance, this material is used often for turbine blades, integral rotors, stators, and other exhaust/combustor components. These parts are mostly manufactured via investment casting. However, the upfront cost of investment casting is more expensive than other manufacturing processes, there are limited foundry suppliers that can produce quality parts, and this is a long lead time process that affects supply chain. A viable alternative to casting Mar M 247 is the binder jetting Additive Manufacturing (AM) process. The problem with binder jetting and most AM modalities is that they are more complicated processes to control than conventional (casting) manufacturing. This leads to large variations in microstructure, porosities, surface roughness, and residual stress, all key factors that significantly influence fatigue performance. In other to qualify binder jetting of Mar M 247 in a rapid fashion for near-term adoption by the turbine engine industry, a rapid fatigue testing capability is an important solution. The work proposed in this abstract will demonstrate the time benefits of an accelerated fatigue test method for gathering Binder Jet Mar M 247 data. The fatigue results will be compared to a standard fatigue test method and dataset. Most importantly, a next generation accelerated fatigue test (lower operational cost and higher frequency) approach and apparatus will be presented with preliminary results.

Presenting Author: Onome Scott-Emuakpor Hyphen Innovations

Presenting Author Biography: CEO and founder of Hyphen Innovations: Over 20 years of experience in propulsion structural integrity R&D. Developed new life prediction models, accelerated test & evaluation methods, and advanced design concepts for flowpath propulsion components. Has more than 150 technical publications covering advanced/additive manufacturing, optimization, sustainment, and dynamic characterization for propulsion structures. Hyphen Innovations has received multiple 3D Printing Awards, including a nomination for this year's 3D Printing Industry Award for Aerospace, Space, or Defense Application.

Authors:

Onome Scott-Emuakpor Hyphen Innovations
Philip Johnson Hyphen Innovations
Mattia Forgiarini Azoth 3D
Tim Noronha TURBOCAM International