Light Weight Solutions for High-Performance Components by Additive Manufacturing

Purpose and goal

Powder bed fusion by electron or laser beam are the most industrialised additive manufacturing (AM) technologies for production of some aerospace engine components and medical implants based on Ti-alloys. The project goal was to extend application to new materials and light weight applications namely manufacturing of the difficult-to-build by AM precipitation hardening Ni-based superalloys for high-temperature applications in gas turbine components and components for rocket engines. The project has shown new opportunities, but also identified challenges.

Expected results and effects

The project has developed technology and built up knowledge along the entire value chain from design, powder, AM-process to verification of properties for high-value components of Ni-based superalloys. The potential to significantly shorter development time and decrease the weight of the high-value components through combination of improved design and properties has been shown. The demonstrator components have been used to prove the proposed concept and will inspire future product development of light weight components fabricated by AM.

Planned approach and implementation

The project work covered the whole production chain; design and topology optimisation, powder development, manufacturing and process development for AM, post treatment and characterisation of powder, material and demonstrators. The research was based on application requirements and included building of a knowledge base concerning required base material properties (nickel based superalloys as powder) and establishment of process parameters to ensure robust high qualitiative manufacturing by powder bed fusion by electron or laser beam.