Haynes 214 high temperature heat exchanger assembly with enclosed heat flow channels and internal fin structures was successfully fabricated using our scalable and expeditious additive manufacturing (SEAM) process, a new metal additive manufacturing (AM) technology developed at Michigan State University (MSU). Three dimensional green objects can be fabricated by selectively photopolymerizing Haynes 214 metal suspension on a powder bed system in a layer-by-layer fashion. An innovative strategy to attain a complete binder removal and high density as well as dimensional accuracy were developed and employed to achieve final metal parts with relative density above 99.5% and no geometrical distortion.
Haynes 214, a nickel-based superalloy, and its oxide dispersion-strengthened (ODS) versions (addition of 0.3, and 1.5 wt. % yttria (Y2O3)) have been successfully fabricated using selective laser melting (SLM). For each feedstock formulation, optimal processing conditions were identified and high temperature tensile testing coupons were produced. Feedstock preparation and laser scanning strategy have been proven to be critical in the dispersion of nanoparticles in the metal matrix, as well as preventing the formation of extensive crack networks. The impact of Y2O3 addition on the high-temperature tensile properties of Haynes 214 was evaluated and discussed.
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