ArticleProgress in additive manufacturing2025
Rapid processing window development of Mo-Si-B alloy for electron beam powder bed fusion.
Article in Progress in additive manufacturing, 2025. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
The multiphase alloy Mo-9Si-8B (at.%) exhibits high oxidation, creep, and fracture resistance at high temperatures. With a melting point of about 2360 °C, it is a promising material for ultra-high temperature applications in turbine engines. However, Mo-9Si-8B (at.%) is difficult to process by traditional manufacturing methods due to its brittleness. Additive manufacturing offers a solution by enabling the production of complex near-net-shape bulk materials (e.g., turbine blades) in a single step. In this study, electron beam powder bed fusion (PBF-EB), which is characterized by extremely high local processing temperatures and associated high powder bed temperatures (i.e., above the brittle-to-ductile transition temperature of the material), was employed to process this Mo-Si-B alloy. The processing window was rapidly developed for the first time using novel strategies that combine high-throughput thermal modeling to predict the melt pool dimensions with in situ electron-optical imaging. High-density bulk Mo-9Si-8B (at.%) samples were successfully fabricated according to the established processing window, and the typical microstructure and phase composition of the as-built samples were analyzed. This novel approach significantly reduces the effort required to generate processing windows, making it highly viable for developing stable processing conditions for new materials in PBF-EB.
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