ICME For Advanced Manufacturing Of Ni Superalloy Heat Exchangers With .

ICME for Advanced Manufacturing of Ni Superalloy HeatExchangers with High Temperature Creep OxidationResistance for Supercritical CO2Christopher Taylor, Taiwu Yu, Pengyang Zhao, Supriyo Chakraborty, SteveNiezgoda, Yunzhi Wang, Brett TosseyDNV GL, The Ohio State UniversityChristopher Taylor18 September 2020DE-FE0031631. AOI 2: Computational Toolsto Support Advanced Manufacturing of FossilEnergy Technologies1DNV GL 18 September 2020This work is supported by the Department of Energy, NationalEnergy Technology Laboratory under contract #DE-FE0031631,with contract manager Dr. Vito CedroSAFER, SMARTER, GREENER

Talk Outline Objective ICME Modeling Tasks High Temperature Oxidation Modeling Creep Modeling Integration with Phase Field Advanced Manufacturing of Multi-Material HX Components Testing and Characterization Milestone Review2DNV GL 18 September 2020

Objective Microchannel heat-exchangers with optimaldurability Targeting additive manufacturing design forsupercritical CO2 power– 700-1000 C, 50 years Optimized material combinations:– Surface skin: alumina former, such as Haynes alloy 224 (hightemperature oxidation resistance)– Internal layer: chromia former having high creep resistance Avoid internal oxidation and dissolution of γ’ innear-surface Develop and Validate an IntegratedComputational Materials Engineering approachto materials design3DNV GL 18 September 2020

ICME StrategyAn integrated modeltackling creep-oxidationfailure mode of superalloymaterials must address: Rate of oxidation Rate of materialsdiffusion Phase transformation Strength evolution Creep dynamics4DNV GL 18 September 2020

High Temperature Oxidation ModelingData curation, analysis and application of a ML-based Arrhenius modelkp A exp(-ΔEa/RT)MSELinear (Ni, Cr, Al)* 1.69Linear* 0.99NN 0.81 𝑊 2𝐴SVM 1.03 𝑘𝑝 𝑡KNN 0.78Tree 0.82Random Forest 0.72*Manuscript complete and preparing to submit by 9-30-20205DNV GL 18 September 2020

Creep Modeling Progress Upcoming Activities Creep modeling framework Simulations of oxidized Haynes 282 samples aredeveloped under NETL Grantunderway and will be detailed in the next reportNo. DE-FE002776 has beenadapted for use to predict Preliminary creep simulations on as received Haynes 224creep in response to thewill also be presented.evolution of 𝛾′ structure due to Continued cleanup of test data from Haynesin-service oxidation. Currently undergoing testingRaw Creep Curves from Haynes Creep data for Haynes 224(provided by VinayDeodeshmukh of HayesInternational) has beensorted/organized andprocessed for use to calibratecreep model Calibration of models forHaynes 282 and 224 Underway6DNV GL 18 September 2020

DICTRA Simulation Setupflux boundary condition with 𝑘𝑝 from ChrisDICTRA Simulation resultConcentration profile𝑜𝑢𝑡𝐽𝐴𝑙2𝑘𝑝 𝑏𝑀0 ()(2𝑘𝑐 𝑡 𝑡0 ) 1/2𝑉𝑜𝑥 𝑎𝑉𝑚Volume fraction of phasesDICTRAcalculationAt 700 , 𝑘𝑝 2.3 10 15 g2/cm4/s4𝜇𝑚Haynes 282 ICMEapproachHomogenizedmodelCrystal plasticity modelPredict the creepbehavior withmicrostructureobtained throughPFM4𝜇𝑚Simulationof creepCrystalplasticitymethodPrecipitates-free zone forms due to the loss of Al.Precipitates dissolves up to 3.4% of total volume in thetwo-phase regionSimulation of particle dissolution and prediction ofheterogeneous microstructure: phase field methodPhase field model (PFM) & resultsDissolutionAl2O3layer(Pint et al. Mat High Temp35:39-49 2018)precipitation𝑜𝑢𝑡𝐽𝐴𝑙

Synthesis of Novel Composition-Gradient Materials Weld overlay to mimic the bi-material and collectoxidation and phase-transformation/ageing dataHaynes 282 sheetwith 224 weldoverlay in placeCross section ofHIP tubular Tubular with PM and HIP/HT– 224 tubular, packed with 282 powder around asteel core– HIP treatment to consolidate and providemetallurgical bond Quintus Technologies has provided at no-costresearch support in advising on methods and tofabricate tubular samples with HIP– Round one: no metallurgical bond was created– Round two: good metallurgical bond, samplescurrently being characterized– Next steps: Heat treatment and creep testingHIP Cans after HIP by Quintus8DNV GL 18 September 2020Microscopic image ofmetallurgical bond region

Testing and Characterization Exposure tests begun8/18/2019 at 900C, 800C, and 700C.Oxidized and y’ depletedregions visible in SEM– First interval exposure is 900 hours (10/4/2019)– Second interval will be 5,000 hours (209 days) orMarch 16, 2020– Finally 10,000 hours (417 days) or October 2020– The environment is carbon dioxide at 1 atm.9DNV GL 18 September 2020Weld-overlayshowing dissimilargrain structure in224/282

Typical Example of high-resolution Imaging in the SEMto characterize the extent of g precipitate dissolutionAlloy 282- Exposed at 925 C,1000 hrsoxide scaleThe depth of g’ depleted regionvaries between 55 – 67 mm.g’ depleted regionsg’ in g matrixImaged with Thermo Scientific Apreo FEG-SEMMicrostructure: Typically 15-20 mm thick oxide scale is observed on the surface with additionaloxygen intrusion of 1-1.5 grain diameter depth along the grain boundary.

Typical Example of high-resolution Imaging combined with EDSSpectroscopy in the SEM to characterize the extent of oxygen intrusionAlloy 282- No Protection from Al-rich oxide layerAlloy 282- Exposed at 925 C,1000 hrs(without the protection from Al-rich oxide layerNi Al Cr MapAlloy 224- Good Protection from Al-rich oxide layerNi Al Cr MapNi Al Cr MapAluminum rich oxide layer can be seen sandwichedbetween the bulk material.

MilestonesDateMilestoneStatus2-1-2019MS 1. ICME Integration PlanComplete2-1-2019MS 2. Sample Fabrication: HighTemperature Oxidation CouponsComplete9-1-2019MS 3. Fabrication of microchannel-likeprototype component11-1-2019MS 4. High temperature oxidation testing11-30-2020Delayed:Materials, COVIDand QuintuspartnershipDelayed10-1-20206-1-2020MS 5. High temperature creep testing ofprototype componentMS 6. Demonstration, verification andvalidation of model9-30-202012DNV GL 18 September 2020Updated TargetDelayed6-1-2021Delayed9-30-2021

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Temperature Oxidation Coupons Complete 9-1-2019 MS 3. Fabrication of microchannel-like prototype component Delayed: Materials, COVID and Quintus partnership 11-30-2020 11-1-2019 MS 4. High temperature oxidation testing Delayed 10-1-2020 6-1-2020 MS 5. High temperature creep testing of prototype component Delayed 6-1-2021 9-30-2020 MS 6 .