CCS and Power Systems

Advanced Energy Systems - Hydrogen Turbines

Computational Materials Design of Castable SX Ni-based Superalloys for IGT Blade Components

Performer: QuesTek Innovations LLC

Project No: SC0009592

Project Description

QuesTek Innovations LLC (QuesTek) is a leader in computational materials engineering and will employ a systems engineering design framework based on existing CALPHAD (CALculation of PHAse Diagrams) multicomponent tools. QuesTek will invoke reliable physics-based models to predict intrinsic freckling potency, alloy hot-tearing tendency during casting, and other casting related defects. The computational materials design will consider trade-offs between the blade property requirements such as creep strength, resistance to topologically close-packed phase formation, tensile strength, corrosion resistance, grain-boundary strength, and SX processing requirements such as freckling resistance, hot-tearing resistance, and a solution heat-treat window that avoids incipient melting. The Phase I focus will be on computationally designing candidate alloys that can provide enhanced castability while achieving increased metal temperature capability of 1050–1100 degrees Celsius. The Phase II program will focus on developing the entire systems-based materials design and validation through casting complex blade components with internal cooling passages using actual OEM (original equipment manufacturer) blade tooling.

QuesTek plans to collaborate with key stakeholders to define specific property goals and processing constraints that will enhance QuesTek’s process-structure models for castability and structure-property models for superalloy design, sketch out microstructural concepts capable of achieving the program goals, and use the enhanced tools to design SX superalloy compositions incorporating these microstructural concepts. Also, QuesTek plans to fabricate baseline commercial alloy compositions (or variants of these compositions) as demonstration IGT tooling castings to characterize their casting behavior and compare it against QuesTek’s model predictions. These model castings and the comparison against predictions will serve as a Phase I concept feasibility demonstration.

A single-crystal model blade (length: 170mm).

Project Details