In a groundbreaking study published in the Journal of Materials Research and Technology, researchers have unveiled the potential of additive manufacturing to revolutionize the production of high-performance, corrosion-resistant components for the nuclear and power generation industries. The study, led by M.L. Hendery of Rolls-Royce plc in Derby, UK, presents the first comprehensive investigation into the use of Laser Powder Bed Fusion (LPBF) to fabricate nickel-based Alloys 690 and 52i.
The research demonstrates that specimens fabricated from gas atomized powder achieved an impressive density of 99.95%, undergoing a conventional solution anneal heat treatment. The study’s findings reveal that LPBF Alloy 52i exhibited superior strength compared to both wrought and LPBF Alloy 690 at ambient and elevated temperatures (300°C), for all build orientations. “The strength differences between orientations were attributed to microstructural anisotropy, consistent with wrought studies,” Hendery explained.
Microstructural characterization uncovered notable differences in pore morphology, carbide distribution, and oxide inclusions. LPBF Alloy 52i, in particular, exhibited plate-like aluminum oxides linked to higher oxygen content in the virgin powder. This insight could be pivotal for optimizing the manufacturing process and enhancing the performance of the final products.
Corrosion testing indicated that both LPBF alloys showed enhanced intergranular corrosion resistance compared to wrought Alloy 690. This improvement is attributed to finer and more continuous grain boundary carbides. “These results support the potential of LPBF Alloys 690 and 52i for structural applications in demanding environments,” Hendery noted, highlighting the significance of these findings for material qualification efforts in nuclear engineering.
The implications of this research are far-reaching for the energy sector. The ability to produce high-performance, corrosion-resistant components using additive manufacturing could lead to more efficient and cost-effective production processes. This could, in turn, drive innovation in the design and manufacture of components for nuclear reactors and power generation plants, ultimately contributing to more reliable and sustainable energy solutions.
As the energy sector continues to evolve, the insights gained from this study could shape future developments in materials science and additive manufacturing. By leveraging the unique properties of Alloys 690 and 52i, engineers and researchers can push the boundaries of what is possible, paving the way for a new era of high-performance, corrosion-resistant components. The study, published in the Journal of Materials Research and Technology, marks a significant step forward in this exciting field, offering a glimpse into the future of energy technology.