Alloy Commercialization for Additive Manufacturing Specific Alloys

Additive Manufacturing (AM) is being used successfully to make superalloy parts for aerospace applications by various commercial manufacturers. These parts are typically for lower strength applications and are made from established alloys that have proven weldability, oxidation resistance, and the heat treatments and hot isostatic pressing procedures are well understood. The alloys currently in use were originally designed for casting or wrought purposes and may not be fully suited for AM. No commercial alloys have yet been made specifically for this dynamic production method, although several have been designed and shown promise at the research level. To successfully bring a new alloy to the commercial market requires working with suppliers that have accredited processes to produce the alloy and with prime contractors on the end part requirements and application. This paper will cover current published alloys designed specifically for additive manufacturing, their strengths and weakness, the various state-of-the-art powderization processes, and the importance of working with established industrial partners for commercial success.