Materials and Methodology - new.pptx Material

Material and methodology is basically ppt representing minor project for development of new superalloys for the critical aerospace applications

1. Materials and Methodology

2. Objective This study aims to design and develop novel high-temperature alloys with enhanced creep resistance by optimizing their chemical composition and microstructure. The focus will be on evaluating the alloys' performance under elevated temperatures and stresses, identifying the underlying mechanisms contributing to their improved creep resistance, and comparing their effectiveness with existing commercial alloys

3. Existing Alloys Alloy Type Maximum Temperature Notable Features Co-Al-Ti Superalloys Up to 1150°C High lattice misfit, regular cubic γ′ precipitates Additively Manufactured IN718 Up to 650°C Improved creep strength, potential ductility issues V-Sc(Al₂Cu)₄ Nanoprecipitates Up to 675 K (~402°C) Coarsening-resistant nanoprecipitates

4. Materials Base metal Alloying Elements Nickel (Ni) Primary matrix element. Provides an FCC (face-centered cubic) crystal structure, excellent ductility, and high-temperature strength. Aluminum (Al) Forms γ′ ( Ni₃Al ) precipitates → precipitation hardening. Contributes to Al₂O ₃ scale for oxidation resistance. Titanium (Ti) Joins Al to form γ′ (Ni₃( Al,Ti )) strengthening precipitates. Improves yield strength and creep resistance. Tantalum (Ta) Refractory addition → enhances creep life. Partitions into γ′ phase → stable strengthening. Tungsten (W) Provides solid solution strengthening in γ matrix. Lowers diffusion → slows creep.

5. We will use CALPHAD tool to decide the percentage of metals in our alloy. CALPHAD is a methodology and set of thermodynamic models We can usually use it via dedicated software (Thermo-Calc, FactSage ). But pycalphad is a mature, open-source Python library that lets you do CALPHAD calculations directly in Python. Percentage of metals

6. Why we choose Ni as a Base material ? Variation of the melting temperatures of the elements with atomic number.Reference : The superalloys/Roger C. Reed /42

7. Why we choose Ni as a Base material ? Correlation of the crystal structures of the transition metals with position in the periodic table.

8. Methodology (Processing Route) Powder Production Powder Compaction Sintering Post-Processing

9. Methodology (Processing Route) Powder Production : This is the first step where metal is turned into powder. For superalloys, the most common method is gas atomization. Here, molten metal is sprayed with high-pressure gas, which breaks it into tiny droplets that cool and solidify into spherical powder particles. These powders are the raw material for building parts . Powder Shaping / Compaction Now the powder is formed into the shape of the part. This can be done in several ways: 1-By pressing the powder in a mold using high pressure. 2-By Cold Isostatic Pressing (CIP), where pressure is applied from all sides using a rubber mold. 3-Using Additive Manufacturing (like 3D printing), where the part is built layer by layer using laser melting.

10. 3. Sintering After shaping, the part is heated to a high temperature (but below melting point). This heating process (called sintering) causes the powder particles to fuse together and become solid. Alternatively, Hot Isostatic Pressing (HIP) is used, where heat and gas pressure are applied together to remove tiny pores and increase density close to 100%. Heat Treatment: 4. Post-Processing Once the part is solid and dense, additional processes are done to improve properties. These include: 1-Heat treatment to develop the desired microstructure (like strengthening precipitates). 2-Surface finishing like machining or polishing. 3-In some cases, hot rolling or forging for better strength . Methodology (Processing Route)

11. A 3D printable alloy designed for extreme environments: https://www.nature.com/articles/s41586-023-05893-0 Powder bed fusion additive manufacturing of Ni-based superalloys: https://www.sciencedirect.com/science/article/pii/S0890695521000390 Advancement of extreme environment additively manufactured alloys for next-generation space propulsion: https://www.sciencedirect.com/science/article/pii/S009457652300334X Recent advances of high-entropy alloys for aerospace applications: https://www.researchgate.net/publication/351638807_Recent_Advances_of_High_Entropy_Alloys_for_Aerospace_Applications_Literature_Review A novel Re-free Ni-based single-crystal superalloy with enhanced creep resistance and microstructure stability: https://www.sciencedirect.com/science/article/pii/S1359645422007157 Architected superalloys: A pathway to lightweight high-temperature materials: https://www.sciencedirect.com/science/article/pii/S1359646225000612 The Superalloys: Fundamentals and Applications: https://patron.group/wp-content/uploads/2017/04/The-Superalloys-Fundumentals-and-Applications-2006.pdf References