Single crystallisation of 3D printed superalloys (SAM1)

Important results from the project

The main goal of the project was to prove that a new concept is applicable to create single crystal material structure in superalloys made by additive manufacturing (AM). This goal is nicely achieved. The results paves the way to enable the use of AM made single crystal components in gas turbines and jet engines. The idea can potentially be expanded to be applied after repair of the old single crystal turbine components by the use of additive manufacturing.

Expected long term effects

The following are expected after reaching into future market: 1- Reducing the fuel consumption in jet engines and gas turbine. 2- Longer life of the 3D printed turbine components operating at ultra-high temperatures 3- Creating a unique possibility for repair of old single crystal turbine blades via 3D printing technologies 4- Enabling the manufacture of ultra-high temperature prototypes and even products for development and production of future generations of hydrogen jet engines and turbines.

Approach and implementation

Here, a simplified single crystallising module was designed and developed according to the guidelines from a patented idea inside an advanced 3D printing machine, called electron beam melting. Afterwards, the parameters for the post processing was developed, tested, and optimised for several superalloy compositions. Materials characterisations was carried out as a feedback to the process until the proof of concept for this technology was achieved for few highly added-value superalloys.