Session: 24-01 Additive Manufacturing - Session 1

Paper Number: 121425

121425 - Mechanical Performance and Material Characterization of Fused Filament Fabricated ABD 900 Superalloy 

ABSTRACT

The material extrusion additive manufacturing (MEAM)/fused filament fabrication (FFF) process for metal 3D printing is actively being sought as a potentially viable manufacturing option for jet engine propulsion materials.  Its low cost, safety/ease in part manufacturing and operation coupled with its potential to efficiently develop deployable ready structures, makes it an attractive option for manufacturing of nickel-based superalloys, compared to laser powder bed fusion (LPBF) additive manufacturing technologies. ABD 900 is a nickel-based superalloy with high strength and corrosion/oxidation resistance at extreme temperatures, which has gained interest in its potential to be additively manufactured through the LPBF technology and reported to yield enhanced mechanical performance at high temperatures as compared with existing nickel-based superalloys, such as LPBF Inconel 718. This novel study is of the first of its kind to report on the ambient tensile response/properties and fracture mechanics exhibited by FFF ABD 900 green test coupons, and to assess the structural integrity of green and sintered cubes through material characterization techniques. Preliminary research findings on green tensile coupons and cubes reveal presence of considerable interlayer delamination and interlayer voids/porosity, with crazing marks evident on sample surface of green tensile coupons. A wide distribution of powder particles sizes is apparent, with most retaining their circular geometry but elliptical/oblong geometry of powder particles evident as well. Upon completion of the initial sintering cycle of cube specimens, presence of warping and a lack of shrinkage are quantifiably evident. The concluding position on the initial sintering trial identifies a need for precise furnace controls and understanding of part temperature as it transitions from green to brown to completed densification.

ACKNOWLEDGMENTS

This study was supported by the US Department of the AirForce AFWERX STTR Phase 1 Contract Number FA864923P0933. The authors would also like to acknowledge Virtual Foundry and Redi R&D for their assistance in filament/sample manufacturing and debinding/sintering process.

Presenting Author: Sanna Siddiqui Florida Polytechnic University

Presenting Author Biography: Dr. Sanna Siddiqui is currently an Assistant Professor at Florida Polytechnic University, with a research expertise in mechanical and material characterization of additively manufactured materials for use in aircraft engine and structural components. She completed her Ph.D. and Master's in Mechanical Engineering, and Bachelor’s in Aerospace Engineering with Magna Cum Laude honors distinction from the University of Central Florida. Dr. Siddiqui has authored multiple peer-reviewed journal and conference publications, and her research has been supported by the National Science Foundation and the U.S. Department of the AirForce.

She has been the recipient of the 2020 American Society of Mechanical Engineers (ASME) Young Engineer Turbo Expo Participation Award, and Florida Polytechnic University's Ablaze 2021 Excellence in Research Award. She is also an alumni fellow of the prestigious National Science Foundation Graduate Research Fellowship, the 2015 Zonta International Amelia Earhart Fellowship, and the 2016 Athena International Emerging Women Leader Fellowship.

Authors:

Sanna Siddiqui Florida Polytechnic University
Dustin Fandetti Florida Polytechnic University
Onome Scott-Emuakpor Hyphen Innovations