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Reactive Synthesis in Additive Manufacturing of an Ultrahigh Temperature MoSiB Alloy

  • Additive Manufacturing for High Temperature Energy Systems: Harvesting Material Data and Modeling
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Abstract

To address the challenges of processing ultrahigh-temperature refractory metal alloys, a novel reactive synthesis-based additive manufacturing technique has been developed to fabricate chemically uniform and dense alloys. The present study demonstrates the reactive additive manufacturing of Mo-4Si-6B (at.%), a high-temperature refractory alloy, using directed energy deposition. For the alloy in the Mo-Si-B system, a premixed blend of molybdenum, silicon nitride, and boron nitride powder was used to make an alloy with the desired composition. A dimensionless number was used to design the process parameters and build efficiency. High-throughput synthesis using build height measurements of individual samples validated the predicted process parameters. Microstructural characterization investigations and indentation hardness testing indicated chemically uniform samples with refined microsegregation in samples with high hardness and no cracking, even with a 10-kg force load. The results demonstrate an effective strategy for additively manufacturing refractory alloys.

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Acknowledgements

The authors would like to gratefully acknowledge the support of the Department of Energy (DOE), Advanced Research Projects Agency-Energy (ARPA-E) Ultrahigh Temperature Impervious Materials Advancing Turbine Efficiency (ULTIMATE) Program (DE-AROOO1431). APT was performed at the Northwestern University Center for Atom-Probe Tomography (NUCAPT). The LEAP tomograph at NUCAPT was purchased and upgraded with grants from the NSF-MRI (DMR-0420532) and ONR-DURIP (N00014-0400798, N00014-0610539, N00014-0910781, N00014-1712870) programs. NUCAPT received support from the MRSEC program (NSF DMR-1720139) at the Materials Research Center, the SHyNE Resource (NSF ECCS-2025633), and the Initiative for Sustainability and Energy (ISEN) at NU.

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Authors and Affiliations

  1. Mechanical and Manufacturing Engineering Program, School of Engineering Technology, Bowling Green State University, Bowling Green, OH, 43403, USA

    Zahabul Islam

  2. Department of Materials Science and Engineering, University of Wisconsin, Madison, WI, 53706, USA

    Zahabul Islam, Longfei Liu, John H. Perepezko & Dan J. Thoma

  3. Department of Materials Science and Engineering, Northwestern University, Evanston, IL, 60208, USA

    Marshal Amalraj & Laurence D. Marks

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  1. Zahabul Islam
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  2. Marshal Amalraj
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  5. John H. Perepezko
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Correspondence to Dan J. Thoma.

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Islam, Z., Amalraj, M., Liu, L. et al. Reactive Synthesis in Additive Manufacturing of an Ultrahigh Temperature MoSiB Alloy. JOM 75, 5037–5045 (2023). https://doi.org/10.1007/s11837-023-06167-w

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