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Optimization of MoNiCr Alloy Production Through Additive Manufacturing.

Michal Duchek1, Daniela Nachazelova1, Martina Koukolikova1

  • 1COMTES FHT a.s., Prumyslova 995, 334 41 Dobrany, Czech Republic.

Materials (Basel, Switzerland)
|January 11, 2025
PubMed
Summary

A new nickel-molybdenum alloy (MoNiCr) was developed for Generation IV reactors. Additive manufacturing using directed energy deposition (DED-LB) successfully produced complex components with excellent mechanical properties and minimal defects.

Keywords:
additive manufacturing (AM)directed energy deposition (DED-LB)miniature tensile test specimens (MTTs)molten salt reactor (MSR)nickel alloy MoNiCrsolidification cracking

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Area of Science:

  • Materials Science
  • Nuclear Engineering

Background:

  • Generation IV reactors utilize molten salt coolant systems, demanding materials that withstand extreme chemical and thermal stresses.
  • The unavailability of suitable materials led to the development of the MoNiCr nickel-molybdenum alloy in the Czech Republic.

Purpose of the Study:

  • To investigate the manufacturing processes for the MoNiCr alloy, focusing on additive manufacturing (AM).
  • To optimize powder characteristics for AM and assess the mechanical properties of additively manufactured components.

Main Methods:

  • Conventional casting, forming, powder atomization, and additive manufacturing (directed energy deposition-laser beam) were explored.
  • Input powder quality, particularly chemical composition, was optimized for AM.
  • Heat treatment was applied to the manufactured components.

Main Results:

  • Additive manufacturing enabled the creation of complex structures despite the MoNiCr alloy's susceptibility to solidification cracking.
  • A test body produced via AM exhibited a low defect rate (0.03%).
  • Achieved mechanical properties include a yield strength of 279 MPa, ultimate tensile strength of 602 MPa, and elongation of 51%.

Conclusions:

  • Additive manufacturing, specifically DED-LB, is a viable method for producing complex MoNiCr alloy components for advanced energy applications.
  • Optimized powder composition is crucial for high-quality AM of MoNiCr, mitigating defects and achieving desired mechanical performance.