3D printed ‘superalloy’ to boost turbine efficiency

The material was developed by scientists from Sandia National Laboratories, in collaboration with Ames National Laboratory, Iowa State University and Bruker Corp. Consisting of 42 per cent aluminium, 25 per cent titanium, 13 per cent niobium, 8 per cent zirconium, 8 per cent molybdenum and 4 per cent tantalum, the multi-principal element alloy (MPEA) was found to be stronger at 800°C than many other high-performance alloys, including those currently used in turbines. These properties would enable turbines to operate at greater efficiency, generating more electricity and releasing less waste heat.

According to the researchers, density functional theory calculations revealed a thermodynamic explanation for the observed temperature-independent hardness, with the Laser Engineered Net Shaping additive manufacturing process also believed to be a factor. The work is published in Applied Materials Today.

“We’re showing that this material can access previously unobtainable combinations of high strength, low weight and high-temperature resiliency,” said Sandia National Laboratories scientist Andrew Kustas. “We think part of the reason we achieved this is because of the additive manufacturing approach.”