Selective Laser Melting of Oxide Dispersion Strengthened Steels

Oxide Dispersion Strengthened (ODS) alloys are a long established class of materials manufactured using powder metallurgy techniques. These alloys can offer exceptional high temperature strength and resistance to radiation damage, thus are envisioned to be used in a number of future nuclear and fossil energy power applications. However, due to the manufacturing steps involved, the overall cost to build components with these materials can be high. This paper presents work conducted to assess the feasibility of applying Selective Laser Melting (SLM) techniques to either coat or direct build on substrates with Fe-based Oxide Dispersion Strengthened (ODS) alloys. SLM is a rapid prototyping technique which can be used to manufacture near net-shape solid components from layered metallic powder beds. Two different geometries were of interest in this study — a simple button configuration with a nickel-base superalloy (IN939) substrate and a more complex hexagonal shaped wall with a mild steel substrate. Powders of PM2000 (a FeCrAl based ODS alloy) were deposited in both cases. Heat treatments were subsequently conducted on these structures to investigate effects of temperature on the bond characteristics and secondary recrystallisation. Electron microscopy examination revealed significant amounts of diffusion between the nickel and the ODS powders which enhances the bond strength. The studies have revealed the existence of a strong bond between the substrate and the interface even after prolonged exposure at elevated temperatures.