| Abstract Scope |
Additive manufacturing (AM) enables transformative design capabilities for gas turbine (GT) components, including integrated cooling features and complex geometries that enhance efficiency and enable next-generation GT technology. ABD®-900AM, a 35% gamma-prime volume fraction nickel-base superalloy, was developed via an ‘alloy-by-design’ approach and offers improved printability and elevated temperature performance compared to traditional cast alloys. To support its adoption in hot-section applications, tensile, creep, low cycle fatigue (LCF), and dwell-fatigue (DF) tests were performed across a range of temperatures. At 760°C, build orientation had minimal impact on mechanical properties, and DF life was comparable to LCF. However, above 800°C, DF performance was reduced and damage morphology resembled that of creep-tested specimens at similar temperatures. Microstructural characterization was also carried out to compare differences in damage morphology between LCF, DF, and creep tests. Compared to traditionally cast superalloys, such as IN738 and IN939, ABD-900AM was found to have superior fatigue performance at temperatures up to 800°C and similar performance above 800°C. These findings provide critical input for life prediction models and support the viability of ABD-900AM in next-generation turbine designs operating under extreme thermal and mechanical conditions. |