Elevated Temperature Testing for Additive Super Alloys

Elevated temperature mechanical testing has always played a key role in the development of new materials that need to withstand extreme conditions, and additive-based superalloys are no different. By subjecting materials to elevated temperatures and mechanical stress, researchers have been able to identify the strengths and weaknesses of different materials, which has allowed them to develop new materials as well as identify ones that are better suited to specific applications.

Playing a particularly important role in the additive manufacturing of superalloys, elevated temperature mechanical testing allows researchers to study the behavior of these materials by simulating the high-temperature, high-pressure environments are often found in real-world applications. (Figure 2)

Figure 2: Today’s elevated temperature testing environments are total systems, comprised of the frame, chamber, sensors, specimen holders and software to help manage and analyze system data.

Why Elevated Temperature Testing?

Insights gained into the material’s microstructure and deformation behavior under different conditions can help identify potential weaknesses or failure modes in the material and inform the development of improved manufacturing processes or material designs. Proper elevated temperature testing can answer significant questions that will provide better performance and efficiency in the application of superalloys produced using additive manufacturing techniques:

What are the effects of different heat treatments on the mechanical properties of additively manufactured superalloys?

• How do different alloy compositions perform under these temperature and stress extremes?
• What strengths and weaknesses do these materials exhibit and how can each be used in specific applications?
• With access to more accurate, repeatable data, what improved predictions can be made about a material’s behavior under extreme conditions?
  

Testing Today’s Superalloys

Modern elevated mechanical testing methods make use of advanced instrumentation and control technology, such as high-temperature furnaces and specialized testing frame and software configurations capable of applying precise loads, strains and temperatures to the specimens under test.

The development of these more advanced testing equipment and techniques has enabled significantly improved accuracy and repeatability, resulting in more precise insight into material behavior under extreme conditions. This has led to an increased understanding of material behavior, with researchers gaining insights into the fundamental physics of material behavior. Ultimately, new materials with improved properties and new production techniques can confidently be brought to market.

Testing standards also play a critical role in the testing of superalloys, so it’s important to note some of the more common ones used in elevated temperature testing. These include ASTM E21, ASTM E139, ASTM E145, ASTM E220, ASTM E1457 and ISO 6892-2, all of which define the test parameters, measurements and results to precisely characterize the response of material to determine its strength, performance and ensure quality to prevent failure in use as well as make informed decisions in terms of which materials to use for a given application.

Elevated mechanical testing continues to evolve and improve with new developments in materials science and technology. This material testing method has helped to improve the safety and reliability of many critical systems, such as aircraft engines and nuclear power plants. By understanding how materials behave under extreme conditions, engineers can design systems that are better able to withstand these conditions without failing or causing harm to people or the environment. When working with new, innovative materials, such as additive manufactured superalloys, confidence in the process is just as important as confidence in the material.

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