"SiAM" - Silicon based intermetallics for Additive Manufacturing

New technological breakthroughs give a constant need for new materials with improved properties. Silicides with good corrosion resistance and high strength at elevated temperatures could be a solution in a wide range of applications, in renewable energy, transport and medicine where the frontiers of possibilities are constantly being pushed. Silicides have properties to perform in extreme environments (high temperatures or corrosive) but are difficult to cast and machine. Additive manufacturing, 3D printing,can make the production of components from such alloys possible. Materials to be used in 3D printing have specifications on size and shape. Different production methods are looked into and a selection of silicides have been produced. The silicides have been tested for mechanical properties and corrosion properties. This has given important input to the end use of the materials. Finaly a selection of the materials were printed in various geometries,- with very positive results. This was important input for the future of the materials and for the continuation of the work with silicides for addtive manufacturing.

The project has shown that silicon-based alloys have a potential as material for additive manufacturing for production of components for use in aggressive and challenging environments. The project has also demonstrated ways of producing such alloys in a cost-efficient way. All together this will bring new materials to the market, a benefit for Elkem but also for the process industry as a whole. Since silicon is one of the earth most abundant material, there is also an environmental impact. Silicon alloys produced by hydro power in Norway generally also have a low CO2 footprint. Also the project has aimed at producing light weight and high strength components which give reduction in fuel and energy use in transport, aviation and space applications

New technological breakthroughs give a constant need for new materials with improved properties. Silicides with good corrosion resistance and high strength at elevated temperatures could be a solution in a wide range of applications, in renewable energy, transport and medicine where the frontiers of possibilities are constantly being pushed. Silicides have properties to perform in extreme environments (high temperatures or corrosive) but are difficult to cast and machine. Significant improvement in high temperature strength and room temperature fracture toughness has been realized in the past decade and recent advances in additive manufacturing can make the production of components from such alloys possible and finally open for wide spread applications of these. Elkem is a major supplier of silicon and intends to develop silicide materials for Additive Manufacturing (AM). To achieve this, the new material must be developed to a level where it can be used in commercial AM equipment and the quality of the produced components must be verified. In this project Elkem with the research partners SINTEF, SINTEF Raufoss and NTNU wil develop a process for production of Si based powder that are suitable for AM and demonstrate that the material can be used to produce components with superior corrosion and mechanical properties. The experimental work will be based on previous experience from Elkem and available thermodynamic data. AM experiments and testing of corrosion and mechanical properties will be carried out. The aim of the project is to develop a process that can be industrialized by Elkem within 2023.