Design and Additive Manufacturing of Ni-based Alloys for Naval Applications

Project: Research project

Project Details

Description

Design and Additive Manufacturing of Ni-based Alloys for Naval ApplicationsAdditive manufacturing (AM) is a revolutionary technolo'gy with potential cost benefits over subtractive manufacturing, and fast delivery of precision objects in almost any geometry. Howev''er, little is known about the strength and corrosion of AM alloys in a marine environment. Hence, this project proposes to uncover t''he fundamental knowledge needed to enable the design and fabrication of the less explored AM alloys for naval applications, with a p'articular applicationof custom fasteners. The present focus is Ni-based AM alloys in the Ni-Cr-Fe-Mo-Nb-Ta-Co-Mn-Cu-Al-Ti system in'spired by Inconel alloys that are widely used in the Navy, such as the gamma double prime-Ni3(Ta,Nb) strengthened Inconel 718 (IN718') and the corrosion-resistant Inconel 625 (IN625). The aim of this proposal is to use computational methods to design alloys for AM that have a combination of high strength and superior seawater resistance. Success in this project relies on thedevelopment of rel'iable thermodynamic and diffusion knowledge, which can be used to tailor nonequilibriumphases in Ni-based AM alloys for naval appli''cations. To accelerate the development of advanced AM alloys, the present project proposes an Integrated Computational Materials Eng'ineering (ICME) approach that includes high throughput first-principles calculations and highthroughput CALPHAD (calculation of phase diagram) modeling for database development and alloy design together with AM processing via the powder bed fusion (PBF) method and characterization for model verification and improvement. The unique features of this project include: (i) high throughput approach'es for both firstprinciples calculations using YPHON code and CALPHAD modeling using ESPEI (pycalphad)code, (ii) simulation of phas''e transformations under AM thermal history, (iii) calculations of Pourbaix diagrams of alloys, and (iv) use of a ~next generation~ P''BF system (ProX 200, 3D Systems) with cutting-edge control of AM processing conditions. The present ICME approach is based on the te''am~s complementary expertise in materials simulation for non-equilibrium processing (Liu), synthesis and characterization of AM allo''ys(Beese), and characterization of naval components (Golumbfskie). When completed successfully,the following fundamental informati'on will be obtained via the present ICME effort:(a) Non-equilibrium microstructure in terms of phase fractions and their size distributions as afunction of AM thermal history;(b) Pourbaix diagrams of AM-processed alloys and their correlations with corrosion behaviors in naval applications;(c) Correlations of beneficial and detrimental phases for strength and corrosion properties; and(d) Optimal combinations of alloy compositions and AM conditions for naval applications.

StatusActive
Effective start/end date5/24/17 → …

Funding

  • U.S. Navy: $450,000.00

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