Research Projects

The proposed research focuses on fabricating single-crystal (SX) Ni-based superalloys using Electron Beam Melting (EBM), an advanced additive manufacturing (AM) technique. SX superalloys are crucial for aerospace and power generation due to their superior high-temperature strength and creep resistance. Traditional crystal-growing methods like Czochralski and Bridgman techniques are limited by geometry and production speed, restricting design flexibility. EBM offers a groundbreaking alternative, enabling complex geometries without requiring single-crystal substrates, unlike Laser-based Direct Energy Deposition (L-DED) or Scanning Laser Epitaxy (SLE). Directional solidification and grain growth can be achieved in EBM by fine-tuning thermal gradients and cooling rates by adjusting the process parameters. At present there is a lack of initiatives in AM of SX superalloys in the country, despite their importance in aerospace and turbine industries. The absence of suitable facilities and limited expertise in this field further hinders progress. ARCI’s advanced EBM facility, coupled with its AM and metallurgy expertise, provides an opportunity to fill this gap. Aligning with the "Make in India" initiative, this research can reduce imports and enhance indigenization for strategic industries. Establishing such capabilities would not only bridge existing gaps but also advance manufacturing technologies, promoting self-reliance and innovation in critical sectors. Research plan: 1. Process Development and Optimization: selecting appropriate Ni-based superalloys and optimizing EBM process parameters. 2. Material Characterization: microstructural analysis using SEM, TEM, and XRD will characterize the crystalline structure of fabricated components. EBSD will confirm the single-crystal nature by mapping grain orientations. Mechanical testing, including high-temperature tensile tests and creep behavior studies, will evaluate the durability and strength of the materials under operational conditions. 3. Application Testing and Scale-Up Strategies: assess the performance of fabricated SX components in high-stress environments and examine the feasibility of scaling the EBM process for industrial applications. Collaborations with industry stakeholders will identify market needs and commercial applications. This research could transform the manufacturing landscape for high-performance SX components, offering a scalable, cost-effective, and geometrically flexible alternative to traditional single-crystal growth methods. From a fundamental perspective, it will advance understanding of crystal growth mechanisms within EBM, paving the way for new applications of SX superalloys in critical industries including aerospace. This project also holds national significance, positioning India as a contributor to the global advancement in single-crystal additive manufacturing.