Session: 18-01: Additive Manufacturing I

Paper Number: 152958

Learnings in the Qualification of ABD®900AM for Turbine, Aerospace, and Energy Applications 

ABD®-900AM is a highly-printable, gamma-prime-strengthened superalloy purposely designed for powder bed fusion (PBF) additive manufacturing (AM) with broad applicability to high-temperature gas turbine, aerospace, defense, and energy applications.  To accelerate the adoption of the alloy, EPRI, with support from America Makes and a team made of AM processing and material data informatics experts, has initiated a first-of-a-kind project to demonstrate qualification of the alloy across multiple AM machines, sites, and companies with the goal of developing requisite SAE feedstock and PBF material specifications with supporting statistical material allowables for future inclusions in MMPDS.  Additional data needed for component design and enhanced specifications (including creep, fatigue, and microstructure) are also being generated for proliferation of datasets for future users of the alloy.   In working through the existing SAE qualification framework, a number of challenges were addressed to adapt the specification requirements to the unique attributes of the alloy, future applications, and machine variables.  This manuscript will address these challenges and highlight the key characteristics (KCs) of the alloy and key performance parameters (KPPs) for manufacturing, which were established in collaboration with NIAR and a public steering committee.  The initial results for a KPP study involving a single batch of powder across five machines considering the impact of layer thickness, heat-input, and heat-treatment will be presented.  These results include evaluation of density and grain size and comparisons to over 100 room temperature tensile tests with the goal of defining an initial S-basis tensile requirement.  Initial comparisons to elevated temperature tensile, low cycle fatigue (LCF), and creep behavior at 800^oC will be explored and presented to prior work and other alloy systems.  Finally, a path will be introduced for expanded qualification activities to a minimum of 10 heats of powder and 20 manufacturing lots.

Presenting Author: John Shingledecker Electric Power Research Institute

Presenting Author Biography: Dr. John Shingledecker is a Principal Technical Executive in the Electric Power Research Institute (EPRI). As a recognized technical expert and thought leader for the Generation Sector; his activities include leading key technical projects in advanced manufacturing methods and materials for current and future generation technologies. His previous roles including leading EPRI’s Cross-Sector Technologies Group and EPRI’s Materials & Repair Program. He has published more than 200 papers, proceedings, and reports on the metallurgy and behavior of engineering alloys and has won numerous awards for transferring technology to industry.

Authors:

John Shingledecker Electric Power Research Institute
Alex Bridges Electric Power Research Institute
Nikki Harless Electric Power Research Institute
Richard Grylls Barnes Global Advisors
Zara Hussain Alloyed
Seba Pereira Siemens Energy
Shankar Srinivasan Siemens Energy
Marco Musto Citrine Informatics
Kenneth Kroenlein Citrine Informatics
James Saal Citrine Informatics