Pack Aluminization Synthesis of Superalloy 3D Woven and 3D Braided Structures

Erdeniz, Dinc; Levinson, Amanda J.; Sharp, Keith W.; Rowenhorst, David J.; Fonda, R. W.; Dunand, David C.

doi:10.1007/s11661-014-2602-9

Cited by 20 publications

(25 citation statements)

References 34 publications

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“…Aluminized 3D woven structures were then homogenized into Ni-Cr-Al alloys and aged for the precipitation of c 0 particles, which are responsible for the high temperature creep resistance of superalloys. Simultaneously, the Ni-Cr-Al wires bonded by solid-state diffusion at their contact points during pack aluminization and homogenization [7]. In the present study, we demonstrate that Al and Ti can be co-deposited by pack cementation onto woven Ni-20Cr structures, which are then homogenized and aged to create Ni-Cr-Al-Ti superalloys where both Al and Ti act as c 0 formers.…”

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confidence: 54%

“…In a recent study, we reported the fabrication of topologically optimized Ni-Cr-Al superalloy structures produced using 3D textile processes [7,8]. Ni-20Cr (all compositions are given in wt.% hereafter) wires were 3D woven or 3D braided, taking advantage of the room-temperature ductility of these wires, and subsequently aluminized via pack cementation [7], a chemical vapor deposition process that has been widely used to create aluminide coatings on Ni-based superalloys for corrosion protection [15][16][17].…”

Section: Introductionmentioning

confidence: 99%

“…Bonding of neighboring wires occurs at necks that are formed by solid-state diffusion or by formation of a transient-liquid phase. Three-point bending tests of the superalloy weaves, after homogenization and aging to achieve a c/c 0 structure, show that, as bonding between wires increases, the materials withstand higher stresses and strains before onset of damage.Architectured cellular materials [1][2][3][4][5][6][7][8], such as honeycombs [4], trusses [5], and wire-based structures [6][7][8], offer a combination of low density and high specific strength, stiffness, permeability, and surface area. These materials have periodic structures that can be designed by using topological optimization models to enhance the desired properties [9-11].…”

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confidence: 99%

“…The main reason for the limited number of existing studies is the difficulty in the processing of such superalloy architectured structures. Particularly, processing of wire-based structures are very challenging due to three manufacturing obstacles: (i) superalloy wires, especially below 500 lm diameter, are difficult to draw, and hence not widely available through suppliers, (ii) if drawn, they are not sufficiently ductile to withstand the bending angles required for weaving, and (iii) if woven, the contact points must be bonded to reach the full potential of mechanical properties, which is difficult due to the presence of oxide layers at the wire surface and low diffusivity, limiting the extent of solid-state bonding.In a recent study, we reported the fabrication of topologically optimized Ni-Cr-Al superalloy structures produced using 3D textile processes [7,8]. Ni-20Cr (all compositions are given in wt.% hereafter) wires were 3D woven or 3D braided, taking advantage of the room-temperature ductility of these wires, and subsequently aluminized via pack cementation [7], a chemical vapor deposition process that has been widely used to create aluminide coatings on Ni-based superalloys for corrosion protection [15][16][17].…”

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confidence: 99%

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Transient liquid-phase bonded 3D woven Ni-based superalloys

Erdeniz

Sharp²,

Dunand

2015

Scripta Materialia

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a b s t r a c tArchitectured Ni-based superalloy scaffolds were fabricated by three-dimensional weaving of ductile Ni20Cr (wt.%) wires followed by gas-phase alloying with aluminum and titanium via pack cementation. Bonding of neighboring wires occurs at necks that are formed by solid-state diffusion or by formation of a transient-liquid phase. Three-point bending tests of the superalloy weaves, after homogenization and aging to achieve a c/c 0 structure, show that, as bonding between wires increases, the materials withstand higher stresses and strains before onset of damage.Architectured cellular materials [1][2][3][4][5][6][7][8], such as honeycombs [4], trusses [5], and wire-based structures [6][7][8], offer a combination of low density and high specific strength, stiffness, permeability, and surface area. These materials have periodic structures that can be designed by using topological optimization models to enhance the desired properties [9-11]. One example is 3D woven metal structures, fabricated from Cu or Ni-Cr wires, that are topologically optimized to provide improved permeability in preferred directions with minimal loss in stiffness for thermo-structural applications [8]. Such cellular materials are of interest for extreme environments, since increased permeability allows for active cooling and results in prolonged service life, or even enables material use, at elevated service temperatures and stresses. A number of studies have been published in the area of periodic cellular nickel-based superalloys, none, however, using topological optimization tools [12][13][14]. The main reason for the limited number of existing studies is the difficulty in the processing of such superalloy architectured structures. Particularly, processing of wire-based structures are very challenging due to three manufacturing obstacles: (i) superalloy wires, especially below 500 lm diameter, are difficult to draw, and hence not widely available through suppliers, (ii) if drawn, they are not sufficiently ductile to withstand the bending angles required for weaving, and (iii) if woven, the contact points must be bonded to reach the full potential of mechanical properties, which is difficult due to the presence of oxide layers at the wire surface and low diffusivity, limiting the extent of solid-state bonding.In a recent study, we reported the fabrication of topologically optimized Ni-Cr-Al superalloy structures produced using 3D textile processes [7,8]. Ni-20Cr (all compositions are given in wt.% hereafter) wires were 3D woven or 3D braided, taking advantage of the room-temperature ductility of these wires, and subsequently aluminized via pack cementation [7], a chemical vapor deposition process that has been widely used to create aluminide coatings on Ni-based superalloys for corrosion protection [15][16][17]. Aluminized 3D woven structures were then homogenized into Ni-Cr-Al alloys and aged for the precipitation of c 0 particles, which are responsible for the high temperature creep resistance of superalloys. Simultaneously, the...

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confidence: 54%

Section: Introductionmentioning

confidence: 99%

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confidence: 99%

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confidence: 99%

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Transient liquid-phase bonded 3D woven Ni-based superalloys

Erdeniz

Sharp²,

Dunand

2015

Scripta Materialia

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“…Here we use it to deposit a 12 lm thick, uniform NiAl coating on the woven Ni20Cr wires [45] at 1000°C for 1 h, as described in detail elsewhere [52]. The NiAl coatings merged at numerous wire contact points to form nodes or solid-state bonds.…”

Section: Experimental Apparatus and Proceduresmentioning

confidence: 99%

Permeability measurements and modeling of topology-optimized metallic 3-D woven lattices

Zhao

Sharp³

et al. 2014

Acta Materialia

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Iron and Nickel Cellular Structures by Sintering of 3D‐Printed Oxide or Metallic Particle Inks

et al. 2016

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Inks comprised of metallic Fe or Ni powders, an elastomeric binder, and graded volatility solvents are 3D-printed via syringe extrusion and sintered to form metallic cellular structures. Similar structures are created from Fe 2 O 3 and NiO particle-based inks, with an additional hydrogen reduction step before sintering. All sintered structures exhibit 92-98% relative density within their struts, with neither cracking nor visible warping despite extensive volumetric shrinkage (%70-80%) associated with reduction (for oxide powders) and sintering (for both metal and oxide powders). The cellular architectures, with overall relative densities of 32-49%, exhibit low stiffness (1-6 GPa, due to the particular architecture used), high strength (4-31 MPa), and high ductility, leading to excellent elastic and plastic energy absorption, when subjected to uniaxial compression. IntroductionCellular materials exhibit numerous advantages over dense materials due to their high specific stiffness, strength, damping, energy absorption, and surface areas. [1][2][3][4] Both iron and nickel, pure or alloyed, have potential uses in cellular architectures for energy storage, [2,[5][6][7] emissions control, [2] catalyst supports, [1,8] and structural applications. [1,3,4,[8][9][10] The micro-architectures of ordered, periodic cellular materials such as scaffolds, honeycombs, lattices, and trusses can be optimized to provide additional improvement on these properties over randomly oriented cellular architectures. [8,[11][12][13] However, the widespread commercial and industrial adoption of cellular metal structures has been hindered by the fact that they are difficult and/or costly to manufacture at sufficient scales and rates relative to traditional metallic structures fabricated using long-established manufacturing methods such as casting. This is especially true for high-melting metals such as Fe and Ni which, unlike Al, are difficult to foam in the liquid state.We recently introduced a versatile and simple process for the additive manufacturing of cellular, metallic architectures, where a liquid ink, consisting of a suspension of metal oxide or metal particles, is first 3D-printed into a structure, and this structure is then subjected to sintering, with an intermediate thermochemical reduction step if oxides are used. [14] A similar direct ink writing approach has been used to produce reticulated sheets of TiH 2 that were then rolled or folded into scrolls or origami shapes [15,16] and Ti-6Al-4V scaffolds for bone implants. [17][18][19] Unlike established metal additive manufacturing methods (e.g., selective laser sintering or electron-beam sintering or melting [20] ), our extrusion-based method can be utilized to 3D-print complex architectures comprised of many layers from an extensive range of materials (e.g., ceramics, metals, biologics) with no required drying time and with a single 3D-printer at room temperature. [14,21] In our previous work, we 3D-printed, reduced,[*] Prof.

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Pack Aluminization Synthesis of Superalloy 3D Woven and 3D Braided Structures

Cited by 20 publications

References 34 publications

Transient liquid-phase bonded 3D woven Ni-based superalloys

Transient liquid-phase bonded 3D woven Ni-based superalloys

Permeability measurements and modeling of topology-optimized metallic 3-D woven lattices

Iron and Nickel Cellular Structures by Sintering of 3D‐Printed Oxide or Metallic Particle Inks

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