Project Grant 2331132

This $122,531 federal Project Grant awarded by the National Science Foundation (NSF)'s Engineering program (CFDA 47.041) supports research into methods to produce columnar-grained structures or single crystals of nickel-based superalloys through directional recrystallization of additively manufactured materials. The goal is to investigate the feasibility of producing a single crystal nickel-based superalloy turbine blade via the integrated approach of additive manufacturing and directional recrystallization, while also gaining fundamental understanding of the underlying physics. Key research objectives include determining if carbides or other particles are necessary to enable columnar grain growth, understanding the recrystallization mechanisms involved, and exploring if high hot-zone velocities and grain selection techniques can be leveraged to produce complex single crystal geometries. The project also aims to train undergraduate and PhD students, as well as host an annual workshop on additive manufacturing technology for undergraduates from Smith College and the University of Massachusetts. If successful, this research could generate new manufacturing capabilities for high-performance alloys, benefiting the aerospace industry.