"SiAM" - Silicon based intermetallics for Additive Manufacturing

Nye teknologiske gjennombrudd øker behovet for nye materialer med forbedrede egenskaper. Silisider, silisiumbaserte materialer, med god korrosjons- og høytemperaturbestandighet kan være løsningen for et bredt spekter av anvendelser innen fornybar energi, innen transport og innen medisin. Silisider har egenskaper som gjør materialene anvendelige i ekstreme omgivelser, høye temperaturer og korrosive miljø, men materialene er utfordrende å støpe og maskinere. Additiv produksjon, 3D printing, kan gjøre produksjon av komponenter fra slike materialer mulig og åpne opp for en bred anvendelse av disse. Materialer for 3D printing har krav til partikkelstørrelse og form. Ulike fremstillingsmetoder er kartlagt, og et utvalg silisider er produsert. Silisidene er mekanisk testet, og resultatene derfra er brukt til optimalisering av sammensetning. Materialene er også korrosjonstestet i ulike miljø. Dette har gitt verdifull input for sluttanvendelse av materialene. Et utvalg av materialene ble til slutt printet i ulike geometrier, med svært oppløftende resultater. Dette ga et ekstra driv for videreføring av arbeidet med silisider for AM.

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.