Laser Powder-Bed Fusion of Ni3Al-Based Superalloys for Turbine Blisks

Reducing aviation's detrimental effects on the environment is of utmost importance, driving the further development of novel materials for jet engines. Currently, Ni superalloys account for over 40% of jet engine components due to their remarkable high-temperature performance. Using exceptionally strong Ni3Al-based superalloys will raise the engine's operating temperature, increase fuel efficiency and lower the exhaust emissions. We propose to fabricate high-pressure turbine blisks with optimized designs for jet-powered drone engines from chemistry-modified IC-221M-EXP alloy using advanced laser powder-bed fusion process. Up to 7% lower density of proposed alloy compared to present Ni alloys is expected to reduce turbine’s weight, and the chemistry tuning to enhance high-temperature performance. The pursuit of ever-more-efficient jet engines with novel aerospace materials will largely impact both large-scale aviation and small-scale specified object production for military operations.