Study: New 3D-printed superalloy could help reduce carbon emissions from power plants

According to a new study, researchers have found that a 3D-printed superalloy could help power plant generate more electricity and produce less carbon.

The superalloy was created by scientists from Sandia National Laboratories in the USA. It has an unusual composition that makes it stronger than other state-of-the art materials currently used in gas turbine machinery.

A superalloy or high-performance metal alloy is an alloy that can operate at a high percentage of its melting point.

The study suggests that there is a new class in similar alloys that could be discovered as the world searches for ways to reduce greenhouse gases emissions.

The team published its findings in the journal Applied Materials Today.

Andrew Kustas, Sandia scientist said that “we’re showing this material can access previously impossible combinations of high strength. low weight. and high-temperature resilience.”

Kustas stated that additive manufacturing is a key reason why they achieved this feat.

Additive Manufacturing, also known by 3D printing is a versatile manufacturing process that is energy-efficient and versatile. A high-power laser is used to flash-melt materials, usually plastics or metals. This is a common printing method. The printer then deposits the material in layers and builds an object as the molten material cools rapidly.

However, this research shows how the technology can be repurposed in a fast and efficient way to make new materials.

Sandia team members used 3D printers to quickly melt powdered metals, then print a sample.

Sandia’s creation is also a significant shift in alloy development, as no single metal makes up more that half of the material. The scientists stated that steel is 98 percent iron and carbon combined, among other elements.

Kustas said, “Iron combined with a pinch of carbon changed our world.”

“There are many examples where two or more elements have been combined to create a useful engineering alloy.

“Now, we are starting to go into four or five materials or more within a single material. Kustas stated that this is when the material science and metallurgical perspectives really start to be interesting and challenging.

According to the US Energy Information Administration (US Energy Information Administration), around 80 percent of electricity comes from nuclear power plants and fossil fuels.

Both types rely on heat to power turbines that produce electricity.

The hot metal turbine parts can make power plants less efficient.

According to Sal Rodriguez, a Sandia nuclear engineer, turbines that can operate at higher temperatures “will convert more energy to electricity while reducing the amount heat released to the atmosphere.” He did not participate in the research.

According to the study Sandia’s experiments found that the new superalloy – 42% aluminum, 25% titanium, 13% niobium; 8 percent zirconium; 8 percent molybdenum; and 4 percent tantalum – was stronger at 800° Celsius or 1,472° Fahrenheit than many high-performance alloys. It also proved stronger when brought back to room temperature.

Rodriguez stated that this is a win-win situation for both the environment and energy.

The findings could not only benefit energy but also other industries.

Aerospace researchers are looking for lightweight materials that can withstand high heat, according to the researchers.

Nic Argibay, Iowa State University scientist, stated that Ames National Laboratory and Sandia are working with industry to see how alloys like these could be used in automotive industry.

“Electronic Structure Theory led by Ames Lab was able atomic origins of these useful property and we are now optimizing this new alloy to address manufacturing and scalability issues,” Argibay stated.