Additive Manufacturing for Energy Applications II: Heat Transfer Components and Joining
Sponsored by: TMS Structural Materials Division, TMS: Nuclear Materials Committee
Program Organizers: Isabella Van Rooyen, Pacific Northwest National Laboratory; Subhashish Meher, Pacific Northwest National Laboratory; Indrajit Charit, University of Idaho; Michael Kirka, Oak Ridge National Laboratory
Thursday 8:30 AM
February 27, 2020
Room: 9
Location: San Diego Convention Ctr
Session Chair: Michael Kirka, Oakridge National Laboratory; Tim Horn, North Carolina State University
8:30 AM Invited
In-situ Qualification of AM 316L for Energy Applications: Federico Sciammarella1; 1Northern Illinois University
The need to lower costs in the production of thermal energy storage systems while also trying to increase their performance has led to the possibility of utilizing AM. It is critical to first know and understand how to characterize AM of a material like 316L which is relatively low in cost compared to Inconel and others. This talk will highlight the research carried out at NIU’s ARMM lab highlighting the ability to monitor in-situ builds of 316L and how we have managed to achieve repeatability across various power levels. This will lay the foundation for future work which will involve the addition of nano-encapuslated PCM’s to help vastly improve the corrosion performance of 316L.
9:00 AM
Additive Manufacturing of Heat Pipes for Microreactor Applications: Donna Guillen1; Clayton Turner1; Adrian Wagner1; Patrick Moo1; 1Idaho National Laboratory
Heat pipes are highly effective devices used to passively transport heat by two-phase capillary action. Their small footprint, light weight and lack of moving parts make them ideal for transportable nuclear microreactors, where size and weight are limited, minimal to no operation and maintenance are required, and high reliability is desired. The use of additive manufacturing allows for the fabrication of heat pipes with performance enhancements, such as microchannels, grooves, arteries, or tailored porosity, which are difficult, expensive or impossible to achieve with traditional fabrication techniques. We are evaluating the capabilities of a digital light printer to produce these geometries by characterizing feature shrinkage, developing an optimal heat treatment recipe, assessing the effects of heat treatment atmosphere and varying print orientation. Computational simulations are being used to estimate performance of the various 3D printed configurations.
9:20 AM Invited
Joining Technologies for Metal Additive Manufacturing in the Energy Industry: Edward Herderick1; Jacob Rindler1; David Schick2; Nate Ames1; 1Ohio State University; 2Proto Precision Additive
To realize the transformational potential for Additive Manufacturing to improve performance and safety of energy generation, it is essential to recognize that AM parts will be integrated into larger assemblies. Joining and welding technologies are the foundation for integrating complex metal products for demanding environments and are the focus of this talk. The presentation consists of 3 parts: overview of metal welding approaches and their capabilities mapped to metal AM; results of original research characterizing microstructure and mechanical properties of aluminum, titanium, and nickel alloy parts joined using friction stir welding, GMAW, GTAW, and impact welding; and views on gaps in research together with the business case for further study.
9:50 AM
High-temperature Mechanical Behavior of Additively-manufactured Mini-channel-embedded Inconel 718 Specimens: Scott Thompson1; Aref Yadollahi2; Jasmin Ahmed3; 1Kansas State University; 2Mississippi State University; 3Auburn University
The development and use of dependable, additively-manufactured metallic parts for high-temperature/pressure applications, such as compact heat exchangers, turbine blades and aerospace structures, continues to receive attention from the energy and aerospace industries. This study investigates the microstructural and mechanical response of Inconel 718 specimens fabricated via the laser-powder bed fusion technique, consisting of novel heat-exchanger-like channels (~1 mm in diameter), during constant and cyclic loading at temperatures as high as 1000 ºC. Microstructural characteristics and failure mechanisms of serviced parts are evaluated using scanning electron microscopy (SEM) within the bulk part and in vicinity of embedded channels. With the aid of computational fluid dynamics (CFD), a set of three channel geometries are selected and then investigated. Each channel was designed with the constraint of surviving high, isostatic pressures and in providing a relatively high Nusselt number for next-generation power cycle coolants such as super-critical carbon dioxide.
10:10 AM Break
10:30 AM
Mechanical Properties of Additively Manufactured Inconel 718 at High-temperature: Abhijeet Dhiman1; Hao Wang1; Vikas Tomar1; 1Purdue University
The use of additive manufacturing in aerospace and the nuclear industry is growing rapidly and the importance to standardize manufacturing process has also been realized. The materials manufactured using additive manufacturing requires characterization at microscale due to microstructural features formed during localized heating in the manufacturing process. Nanoindentation has emerged as a robust and repeatable technique to detect and characterize mechanical properties and deformation behaviors at the microscale. In this work, mechanical properties of conventionally forged Inconel 718 were compared with the additively manufactured Inconel 718 at room temperature and elevated temperatures of 350C and 650C. Selective laser melting was used for additive manufacturing of Inconel 718. The mechanical properties including hardness, reduced modulus and creep rate were obtained using Nanoindentation technique. Compared to room temperature, the decrease in the reduced modulus and hardness for additively manufactured samples was lesser than the conventional sample at 650C.
10:50 AM
Fatigue Strength Prediction of As-built Ti-6Al-4V Components, Produced by Electron Beam Melting (EBM) Technology: Md Jamal Mian1; Leila Ladani1; 1Arizona State University
TTi-6Al-4V alloy has been used in various industrial applications. In many of the applications, material experiences cyclic loading and fatigue. It is shown in literature that most of the fatigue cracks initiate from surface defects rather than internal defects. Electron beam melting method has shown to produce rougher surfaces compared to laser beam melting technology, thus aggravating the issue of fatigue. Additionally, in AM parts, parameters such as waviness and roughness depend on direction of built. Therefore, fatigue failure may vary depending on the part build orientation with respect to loading direction. In this study, E-beam built parts are analyzed for surface roughness in different orientations and sides. This analysis is then used as basis for a quantitative method using Murakami’s √area parameter model to calculate the fatigue strength of the parts. The results are compared against literature and were found to correlate well.
11:10 AM
Additive Manufacturing Research for the Energy Sector: Hani Henein1; Ahmed Qureshi1; Tonya Wolfe2; 1University of Alberta; 2InnoTech Alberta
Additive manufacturing (AM) is garnering interest for the production of functional parts in the Canadian Energy Industry, specifically in the mining sector. However, the current available laser based and electron beam technologies are unable to meet the size and productivity requirements for this industry. Several approaches in AM are being explored and will be discussed: Plasma-Transfer Arc (PTA-AM) and Fused Filament Fabrication. For both techniques 60wt%WC-Ni alloy metal matrix composite is used and 17-4PH is used in PTA-AM. This talk will present on-line sensing that is used for each of the AM techniques as well as some simple geometries produced and their characterization. The role of powder quality will also be addressed and a comparison with weld overlay coatings will be presented.