In-situ alloy homogenization from raw elements
It is often the case for a research project based on materials science, and the invitations are looking to test multiple different materials or alloys to find the best-suited one. While testing multiple alloys in bulk form produced by casting technologies is really easily obtained, many different alloys in the form of powder – especially spherical powder needed for multiple technologies, including additive manufacturing or thermal spray- is challenging.
Similarly, AMAZEMET partners faced challenges in the Sunflower project under the Clean Energy Transition Partnership – CETP call. The project aims to develop novel solar energy receivers for Concentrated Solar Power (CSP) plants that could be both more efficient (from ~20% to ~40%) and manufactured more sustainably. The project investigates 2 paths to reach its goals regarding Energy absorbed – SiC, a ceramic material, and FeCrAlY heat-resisting group of alloys as candidates to fulfill the project’s goals.
FeCrAlY alloys are known for their durability at high temperatures. They resist oxidation and maintain strength, which makes them useful in heating elements, industrial furnaces, and catalytic converters. These alloys are favored in nuclear reactors because they withstand radiation and extreme heat. The yttrium helps protect the material by stabilizing its surface layer, improving performance in challenging environments. FeCrAlY alloys are chosen for applications where both high-temperature strength and corrosion resistance are essential, providing reliable performance in various industrial settings.
AMAZEMET takes the role of leader of the 1st project, Work Package – Metal Alloy development, which involves defining the requirements for the materials and feedstock. Considering the sustainability aspect, raw elements were used to create 9 custom FeCrAlY alloys with varying content of Cr (10, 15, 20 wt.%) and Al (5, 7.5, 10 wt.%). Raw elements in the form of pellets and chips were used with a purity of at least 99.9 %. Each batch was placed in a homogenization water-cooled copper bowl and melted and homogenized using a focused plasma torch. Increased energy density and gas flow compared to TIG torches typically used in arc melting enhance the efficiency of melting and mixing of elements. The melted buttons were flipped upside down and melted for 2nd time to enhance the homogeneity of arc-melted buttons.
The arc-melted buttons have been sectioned into 3 pieces – no inhomogeneities have been observed on the cross sections of the arc-melted buttons.
They were subsequently atomized using a rePOWDER system with 40 kHz, yielding highly spherical powder intended for consolidation using SPS at Fraunhofer IFAM. The sintered disc will be tested in solar furnaces by researchers from CIEMAT. The best-performing alloy will be selected for the project’s next stage, involving energy receivers with complex shapes manufactured with powder bed fusion electron beam technology.
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BARTOSZ MOROŃCZYK
APPLICATION ENGINEER
Responsible for scientific collaboration and project management, being a Project Manager for M-ERA.NET IronWorkCoat and CETP ''Sunflower'' projects and Researcher in Pathfinder project AM2SoftMag. My field of expertise is:
- Laser Powder Bed Fusion – process optimization for novel alloys
- Materials Characterization – focused on metal powders
- Thermal Spray
PhD candidate at Warsaw University of Technology - Materials Science. His PhD topic is: „Processing of Fe-based soft magnetic BMGs by laser Powder Bed Fusion”.
