Abstract

High performance Nickel-based superalloys are known to be difficult-to-weld materials due to their complex chemical compositions. Consequently, these alloys become challenging when processed via additive manufacturing (AM) technologies. In this study, new AM Nickel-based superalloys were developed for applications in gas turbines, with particular regard to hot gas path components like turbine vanes for Baker Hughes products. The alloy development was driven by the performance required for the specific components, with emphasis on creep and oxidation resistance.

This paper describes all the steps that led to design and manufacture of an AM alloy free of defects and with required performance. In particular, the alloy design approach based on thermodynamics calculations and fast experimentation is described. AM process parameters development along with post-printing treatments (hot isostatic pressing and heat treatments) are discussed in conjunction with the emerging mechanical properties. An assessment on the oxidation behaviour of a selected alloy is presented.

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