Advancing Aerospace and Defence Through Additive Manufacturing of High-performance Alloys

The current geopolitical tensions and conflicts have underscored the critical need for advanced aerospace materials capable of withstanding extreme operational conditions. High-temperature alloys are essential for the performance and reliability of aerospace components, especially in military and defence applications where the demand for durable and high-performance materials is increasing. Additionally, additive manufacturing methods, such as laser beam powder bed fusion (PBF-LB), enable the production of intricately shaped components on demand, reducing lead times and material waste. These additive technologies help the aerospace industry meet the urgent demands of modern defence. Given that not all materials are suitable for the specific requirements of additive manufacturing, particularly those prone to solidification and liquation cracking, there has been a significant increase in recent research focused on the development of alloys explicitly tailored for PBF-LB process.
Hence, our research focuses on examining the impact of PBF-LB processing parameters, such as laser power, scanning speed, and layer thickness, on the microstructure and mechanical properties of the ABD®-900AM alloy, specifically designed for use as feedstock in PBF-LB. ABD®-900AM is engineered to demonstrate superior creep and tensile strength, along with exceptional resistance to corrosion and oxidation, with a working temperature range extending up to 900°C. This alloy exhibits creep strength similar to Inconel 939 and Inconel 738 alloys, while also offering enhanced resistance to cracking during both manufacturing and heat treatment processes. Furthermore, we are adjusting PBF-LB manufacturing parameters to achieve high surface quality and accurate CAD model rendering of the fabricated elements to minimise the need for surface finishing and mechanical postprocessing. Preliminary results indicate that optimized PBF-LB processing can yield high-temperature alloys with improved yield strength and creep resistance, which are essential for commercial and military aviation applications.