Additive manufacturing of components for high-temperature, carbon-rich environments using coking and metal dusting suppressing, catalytic inhibiting base materials.

 

The destruction of materials by corrosion is estimated to cost US$3.3 trillion annually worldwide [1]. One of the most aggressive forms of corrosion is metal dusting. In this, the material is decomposed into pure metal powder due to a carbon-rich hot gas environment. The conventional material concepts include a chromium oxide layer to protect the material against corrosion. The Difficulty is that the protection is only temporary due to the low oxygen partial pressures of the gas medium, so that sudden failure can occur rapidly. New concepts, such as the nickel-copper alloy, appear to offer a solution to this challenge. The alloying element copper has an inhibiting property. As a result, carbon can no longer be deposited from the gas atmosphere into the material, preventing the diffusion and deposition of graphite. Failure of the component would thus be precluded (See Figure 1).

  Abbildung 1 Copyright: © [2] / IEHK

Additive manufacturing is of key importance for development and research, as the new material concept still has some unresolved issues. For example, the laser powder bed fusion process can be used to demonstrate, on the one hand, the possible relationship between the microstructure, the process parameters and the corrosion resistance of the nickel-copper materials. On the other hand, the additive manufacturing offers the possibility to prove a possible influence of further alloying elements (e.g. manganese and aluminum) within the nickel-copper alloys in a very short time, since the adaptation period from the production of the starting material to the samples is very short.

[1] https://dechema.de/%C3%9Cber+DECHEMA/Presse/Pressemitteilungen/Archiv/2011/19_2011+Weltkorrosionstag+2011-p-123972.html [Stand 24.03.2021]

[2] NISHIYAMA, Y, K MORIGUCHI, N OTSUKA und T KUDO. Improving metal dusting resistance of transition-metals and Ni-Cu alloys. Materials and Corrosion. 2005. No. 11, p. 806–813. DOI 10.1002/maco.200503883.