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Methodology Development for Ultra-High Temperature Mechanical Testing of Additively Manufactured Refractory Alloys

Orsborn, Kelly R
http://orcid.org/0009-0004-3178-4773
http://rave.ohiolink.edu/etdc/view?acc_num=osu1723827941495366

Abstract Details

2024, Master of Science, Ohio State University, Welding Engineering.
As Additively Manufactured (AM) refractory alloys are developed for extreme temperature environments, new methodologies evaluating their fitness for service must be developed. AM processes alter the properties and behavior versus wrought counterparts, and as much of the refractory alloy development ended decades ago, the adaptation of AM to refractory alloys introduces new challenges. Because refractory alloys are desirable for their high strengths at very high temperatures, they must be tested at these temperatures. A Gleeble 3800 thermomechanical simulator was modified and used to evaluate mechanical properties and oxidation of AM refractory alloys at their expected service temperatures, ranging from room temperature to thousands of degrees Celsius. Both the fixturing and sample’s geometry for this new test were designed considering the joule heating utilized by the testing system as well as the potential risk of damaging standard components inside the test chamber. Oxidation during testing was manipulated by controlling the vacuum in the chamber and utilizing argon backfills. AM C103, TZM, and tungsten samples were built based on the designs created for this research and were tensile tested up to ultra-high temperatures. Mechanical properties were evaluated with the measurement of ultimate tensile strengths (UTS), yield strengths (YS), elongation, and strain-hardening coefficient as a function of temperature. C103 was the highest performing material, with an average UTS of ~650 MPa and over 25% elongation at room temperature. Strength at 500 °C - 1000°C showed similar behavior, but the strength from 1200 °C -1400 °C rapidly declined, and YS and UTS values were identical. Fractography analysis of the fracture surface indicated ductile fracture for the C103, while brittle fracture was observed in TZM and tungsten. Electron Backscatter Diffraction (EBSD) maps and pole figures of the C103 samples enabled the evaluation of the microstructures at the transition section and fracture surface, which indicated a textured microstructure and the presence of dynamic recrystallization at high temperatures (1000 °C -1400 °C). The considerations guiding the development of this new high-temperature testing method are discussed alongside recent findings to provide insight into the significant deviations from traditional mechanical testing methods required to accommodate these extremely high temperatures.
Boian Alexandrov (Committee Member)
Antonio Ramirez (Advisor)
133 p.
Engineering; Materials Science; Mechanical Engineering
Additive Manufacturing; Refractory Alloys; High Temperature Mechanical Testing; C103; TZM; Tungsten; Thermomechanical Simulator;

Recommended Citations

Citations

  • Orsborn, K. R. (2024). Methodology Development for Ultra-High Temperature Mechanical Testing of Additively Manufactured Refractory Alloys [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1723827941495366

    APA Style (7th edition)

  • Orsborn, Kelly. Methodology Development for Ultra-High Temperature Mechanical Testing of Additively Manufactured Refractory Alloys. 2024. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1723827941495366.

    MLA Style (8th edition)

  • Orsborn, Kelly. "Methodology Development for Ultra-High Temperature Mechanical Testing of Additively Manufactured Refractory Alloys." Master's thesis, Ohio State University, 2024. http://rave.ohiolink.edu/etdc/view?acc_num=osu1723827941495366

    Chicago Manual of Style (17th edition)

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This open access ETD is published by The Ohio State University and OhioLINK.
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