Optimization of MoNiCr Alloy Production Through Additive Manufacturing

One of the concepts behind Generation IV reactors is a molten salt coolant system, where the materials for the reactor itself and for the primary and secondary circuit components are subjected to extreme chemical and thermal stresses. Due to the unavailability of these materials, a nickel-molybdenum alloy known as MoNiCr has been developed in the Czech Republic. This paper discusses the manufacturing process for the MoNiCr alloy, covering conventional casting technology, forming, powder atomization, additive manufacturing (AM) using the directed energy deposition (DED-LB) process, and final heat treatment. Special attention was given to the quality of the input powders for additive manufacturing, particularly regarding the optimization of the chemical composition, which significantly influenced the quality of the additively manufactured components. AM enables the realization of complex structural designs that are critical for energy applications, despite the high susceptibility of the MoNiCr alloy to solidification cracking. Through AM, a test body was successfully produced with a maximum defect rate of 0.03% and the following mechanical properties: a yield strength (YS) of 279 MPa, an ultimate tensile strength (UTS) of 602 MPa, and an elongation (El) of 51%.