title: efficient alloy and process design for additive

Research Team: PI: Raymundo Arróyave, Texas A&M University Co-I: Ibrahim Karaman, Texas A&M University Co-I: Alaa Elwany, Texas A&M University Co-I: James Mabe, The Boeing Company Research Objectives Overall goal: Develop and demonstrate a framework for the co-design of chemistry and processing window for printable, high-performing refractory alloys Objectives: a. Identify alloy chemistries satisfying performance (high- temperature yield strength, room temperature ductility) and printability (slow solidification rate, narrow solidification range) requirements. b. Assess Laser Powder Bed Fusion Additive Manufacturing (AM) process window resulting in fabricated AM parts free of macroscopic defects. c. Print and characterize (including tensile tests at 2,000 0 C) test coupons of top performing alloys d. Design and fabricate aerospace-relevant component capable of operating at high-temperatures Approach • Use state of the art (SOA) alloy search schemes to identify feasible alloy regions, combining CALPHAD phase stability predictions, physics-and ML-based property models • Use beyond SOA approaches to batch Bayesian Optimization of materials in combination with advanced alloy prototyping experimental facilities to discover candidate alloys • Synergistic combination of SOA physics-based models, machine learning and experiments within an integrated framework to assess printability of top performing alloys • Fabrication of test coupons and characterization of strength at ultra-high temperatures using SOA facilities • Design and fabrication of aerospace-relevant parts by synergistic collaboration between Boeing and TAMU Potential Impact • Demonstration of accelerated alloy + processing co- design in the refractory alloy space • Development of new refractory alloys with strengths superior to W-based alloys, lower density and better printability • Demonstration of ability to fabricate complex AM refractory parts for aerospace applications Advanced Characterization and Testing Single Tracks Batch-wise Improvement Loop Top performing alloys from each iteration Filters for Design Space Reduction Printability High Temp Testing Physics-based Performance Filters Phase Stability Predictions (CALPHAD) Fabrication A Batch-wise Integrated Framework for the Alloy+Process Co-design of Additive Manufacturable Refractory Components Title: Efficient Alloy and Process Design for Additive Manufacturable Refractory Alloys

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Page 1: Title: Efficient Alloy and Process Design for Additive

Research Team:PI: Raymundo Arróyave, Texas A&M UniversityCo-I: Ibrahim Karaman, Texas A&M UniversityCo-I: Alaa Elwany, Texas A&M UniversityCo-I: James Mabe, The Boeing Company

Research ObjectivesOverall goal: Develop and demonstrate a framework for

the co-design of chemistry and processing window forprintable, high-performing refractory alloys

Objectives:a. Identify alloy chemistries satisfying performance (high-

temperature yield strength, room temperatureductility) and printability (slow solidification rate,narrow solidification range) requirements.

b. Assess Laser Powder Bed Fusion AdditiveManufacturing (AM) process window resulting infabricated AM parts free of macroscopic defects.

c. Print and characterize (including tensile tests at2,0000C) test coupons of top performing alloys

d. Design and fabricate aerospace-relevant componentcapable of operating at high-temperatures

Approach• Use state of the art (SOA) alloy search schemes to identify feasible alloy

regions, combining CALPHAD phase stability predictions, physics-based models and ML-based property models

• Use beyond SOA approaches to batch Bayesian Optimization of materials in combination with advanced alloy prototyping experimental facilities to discover candidate alloys

• Synergistic combination of SOA physics-based models, machine learning and experiments within an integrated framework to assess printability of top performing alloys

• Fabrication of test coupons and characterization of strength at ultra-high temperatures using SOA facilities

• Design and fabrication of aerospace-relevant parts by synergistic collaboration between Boeing and TAMU

Potential Impact

• Demonstration of accelerated alloy + processing co-design in the refractory alloy space

• Development of new refractory alloys with strengthssuperior to W-based alloys, lower density and betterprintability

• Demonstration of ability to fabricate complex AMrefractory parts for aerospace applications

Advanced Characterization

and Testing

Sing

le T

rack

Batch-wise Improvement Loop