A Novel Approach to Additive Manufacturing of Refractory Metals Without Cracks

Researchers at Purdue University have developed a method for the crack-free cladding of the refractory alloy CoMoCrSi on Haynes 282, an alloy in jet and rocket engines and industrial gas turbines. When CoMoCrSi is clad onto Haynes 282, it cracks due to differences in temperature and differences in the coefficients of thermal expansion for the two materials. Previous attempts to alleviate this problem involved preheating the substrate. However, preheating the substrate dilutes the coating. The method developed by the Purdue researchers avoids cracking and dilution by combining laser cladding and remelting.

Technology Validation: Unlike the preheating methods used in prior art, the remelting process yielded minimal to no dilution at the surface.

Advantages:

- No dilution of CoMoCrSI

- Crack-free

- Strong bonding between CoMoCrSi and substrate

- Versatility in size and type of surface for coating

Applications:

- Jet engines

- Rocket engines

- Industrial gas turbines

Publication:

https://www.sciencedirect.com/science/article/abs/pii/S0257897223009118

TRL: 3

Intellectual Property:

Keywords: CoMoCrSi, Crack-free coating, Haynes 282, laser additive manufacturing of refractory alloys, Laser cladding of refractory alloys, laser power-bed fusion, Selective Laser Melting, Tribaloy T400