The Additive Technologies Center (ATC) is testing two heat-resistant alloys for additive manufacturing of aircraft engine components.
The alloys are being evaluated for use with selective laser melting, with the materials designed to withstand temperatures of up to 1,000°C and high mechanical loads. Initial 3D-printed turbine wheel prototypes are undergoing testing under conditions designed to replicate engine operating environments.
Roman Malinin, head of the ATC Central Measurement Laboratory, said: “ATC specialists have done extensive work adapting casting alloys for selective laser melting technology, which is used to manufacture many aircraft engine components. Alloys originally developed for casting demonstrate good resistance to long-term loads at high temperatures. This means that power plants can become more advanced, reliable, and durable. Using these new alloys in 3D printing will allow them to compete with existing nickel- and cobalt-based alloys. Printing technology development is currently underway, and long-term strength testing is underway.”
The ATC is also refining selective laser melting parameters to improve the surface finish of printed components. Surface roughness is an important factor for engine parts because it affects the amount of machining required after additive manufacturing.
A smoother surface after printing can reduce subsequent machining operations, potentially lowering production time and manufacturing costs.
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The current work is focused on validating the alloys and manufacturing process for high-temperature engine components. Long-term strength testing is also underway to assess their suitability for service under sustained thermal and mechanical loads.
The development could support additive manufacturing for complex aircraft engine components, where material performance and post-processing requirements are key considerations.
