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High Temperature Alloys

Research Field High Temperature Alloys

Our research focuses on material development and process technology (investment casting and powder injection molding) of high temperature alloys, in particular Nickel-base superalloys.

Mitarbeiterfoto Alexander Müller

Alexander Müller, M.Sc.

Mitarbeiterfoto Paul Git

Paul Git, Dipl.-Phys.

Mitarbeiterfoto Andreas Meyer

Andreas J. Meyer, M.Sc.

Project B1 focuses on the investigation of the newly developed FCBC (Fluidized Carbon Bed Cooling) process for the single crystalline solidification of superalloys. In comparison with commercially available investment casting processes it could be shown that FCBC benefits from a higher cooling potential. In combination with a dynamic baffle a higher axial temperature gradient will evolve. Objective of the upcoming project period is the improvement of the process understanding as well as the process optimization, carried out on a 10 kg prototype plant. A further point of interest is the exploitation of the increased microstructural homogeneity for alloy development.

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Project B2 explores selective electron beam melting, which belongs to the additive manufacturing technologies, for the processing of single-crystalline superalloys. Especially the potential of the inherent high cooling rates is investigated. These lead to an ultra-fine and directional solidified microstructure. The main challenge of this project is to develop innovative processing strategies based on a sound theoretical process understanding in order to produce crack-free and preferably single crystalline samples, also with higher geometric complexity.
 

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A new numerical tool will be explored that supports the experimental alloy developer in defining new compositions with potential for high strength. Starting with a composition space that is defined by the developer based on his metallurgical experience and his design goals, the numerical tool will propose the most promising compositions. The research program will on the one hand address open questions regarding the mathematical optimization in this application and on the other hand new models for predicting the relevant material properties.

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The scientific service project of SFB/Transregio 103 takes care of the procurement and processing of all project materials.

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Das Kernziel des Vorhabens ist ein verbessertes mechanistisches Verständnis der Heißrissbildung bei der Erstarrung von Nickelbasislegierungen. Die Ergebnisse können in einem eventuellen Nachfolgeprojekt zur Entwicklung neuer besser gießbarer Legierungssysteme genutzt werden. Auf Basis umfangreicher Vorarbeiten gehen wir von der Erkenntnis aus, dass die Restschmelze in gut gießbaren Legierungen lokalisiert vorliegt und nicht filmartig verteilt ist. Im Antragszeitraum…

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We focuse on the development of new alloys for the requirements of industry as well as on clarifying scientific questions. Numerical tools based on CALPHAD (Calculation of Phase Diagrams) calculations as well as further property modeling approaches are used to predict thermomechanical properties of the materials and to optimize them in terms of the desired characteristics. For this purpose the software tool MultOpt was developed. In general, the potential of promising alloys are a compromise between various relevant properties, which are represented in the form of Pareto fronts. The user can decide which alloy is fitting best by weighting up the importance of the conflicting properties. The numerically determined alloy is then cast by an institute own Bridgman furnace. The numerical tool HeatOpt, a coupling of CALPHAD with the phase field method, is used to determine suitable heat treatment parameters, which are applied after alloy manufacturing. Furthermore, the alloys are characterized in terms of their microstructures and mechanical properties. The values determined experimentally are compared with the previously calculated values and an adaptation of the respective numerical modeling is carried out for data with a large discrepancy.

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Metal Injection Molding (MIM) is a near-net-shape process for manufacturing of high precision components that combines the advantages of sintered materials and the potential of shaping of plastic injection molding technology. Metal powders are mixed with a binder component, heated and injected into a mold similar to injection molding of plastic parts. Then the binder is released with the aid of solvents and/or thermal processes and the powder is compacted by a subsequent sintering step. The elimination of costly post-processing steps and material savings make this production method a more cost-effective alternative to conventional manufacturing processes. Powder metallurgic components are employed in almost all areas of technology.

The current research at ZMP focuses on the metal injection molding of Nickel-based superalloys and Iron-based ODS alloys. Due to their excellent mechanical properties at high temperatures and their high corrosion and oxidation resistance they are suitable for use in stationary gas turbines and aircraft engines.

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Based on experience with the LMC (Liquid Metal Cooling) process, it is focused on the investigation of the newly developed FCBC (Fluidized Carbon Bed Cooling) process for the single crystalline solidification of superalloys. In comparison with commercially available investment casting processes it could be shown that FCBC benefits from a higher cooling potential. In combination with a dynamic baffle a higher axial temperature gradient will evolve. Objective is the improvement of the process understanding as well as the process optimization, carried out on a 10 kg prototype plant. A further point of interest is the exploitation of the increased microstructural homogeneity for alloy development.

CRC DFG TR 103 “From Atom to Turbine Blade” (http://www.sfb-transregio103.de/).

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