The Need

Current additive manufacturing (AM) methods for high-performance alloys, such as Inconel 718, face significant challenges: poor control over microstructure, high porosity, and limited resistance to harsh environments (e.g., high temperature, hydrogen attack). These issues lead to premature failure, embrittlement, and reduced service life in critical applications like heat exchangers for hydrogen systems. There is a strong need for AM technologies that enable real-time tunability of material properties and enhanced durability.

The Technology

OSU engineers have developed a hybrid additive manufacturing system that integrates a directed energy deposition (DED) process with a magnetic field and multiple powder nozzles. The system enables precise control of melt pool dynamics and microstructure by applying a magnetic field during deposition and injecting secondary powders (e.g., ceramics, alloying agents) at controlled velocities and locations. This approach allows for real-time tuning of composition, grain structure, and reinforcement, resulting in components with superior performance in demanding environments.

Commercial Applications

• High-temperature, hydrogen-resistant heat exchangers for energy and chemical industries
• Aerospace and automotive components requiring enhanced creep and fatigue resistance
• Advanced power generation and hydrogen storage systems
• Customizable metal matrix composites for harsh service conditions

Benefits/Advantages

• Real-time, localized control of microstructure and composition
• Reduced porosity, refined grains, and improved mechanical properties
• Enhances resistance to hydrogen embrittlement, creep, and fatigue at elevated temperatures
• Reduces manufacturing steps, material waste, and overall carbon footprint