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Additive Manufacturing of Large Scale Heat Exchanger (Topic 18a)

Award Information
Agency: Department of Energy
Branch: N/A
Contract: DE-SC0017742
Agency Tracking Number: 230462
Amount: $224,906.73
Phase: Phase I
Program: STTR
Solicitation Topic Code: 22a
Solicitation Number: DE-FOA-0001619
Timeline
Solicitation Year: 2017
Award Year: 2017
Award Start Date (Proposal Award Date): 2017-06-12
Award End Date (Contract End Date): 2018-03-11
Small Business Information
20 New England Business Center
Andover, MA 01810-1077
United States
DUNS: 073800062
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Kalvis Terauds
 (978) 738-8223
 kterauds@psicorp.com
Business Contact
 David Weatherby
Phone: (978) 738-8107
Email: weatherby@psicorp.com
Research Institution
 Concurrent Technologies Corporation
 Kevin Klug
 
100 CTC Drive
Johnstown, PA 15904-1935
United States

 (910) 437-9904
 Domestic Nonprofit Research Organization
Abstract

Nickel super alloys, such as InconelĀ®, are leading candidates for fossil energy-based power production components due to their resilience in extreme environments. A significant technical roadblock to the implementation of nickel-based power plant systems is the inability to produce large-scale components in a cost competitive manner. We will address the problem of manufacturing large, low-cost superalloy components with a combination of innovations which includes directed laser deposition of Inconel for components up to 10 feet in length, and a hybrid additive/removal based manufacturing process. This Phase I program will develop the processing technology necessary to produce large high- performance extreme environment heat exchanger components by additive manufacturing. We will achieved this by utilizing directed energy deposition of Inconel. The Phase I program will also develop a hybrid additive/removal approach for large parts which will eliminate traditional manufacturing steps and greatly reduce production time, enabling large-scale additive manufacturing to compete directly with current industry standard manufacturing processes. The transition to higher performance power generation energy cycles, such as supercritical carbon dioxide cycles, will offer tremendous benefit in power plant efficiency, cost, and safety. Successful development of an additive manufacturing approach for large extreme environment components is considered an enabling technology for next generation power plant heat exchangers. The manufacturing technology in this Phase I program will be developed for commercial heat exchanger components by 2022. The long term market opportunity for these components will continue to expand over the next 20 years as new power plants come online with traditional manufacturing being replaced by additive manufacturing. This technology also has commercialization potential in other energy applications such as power plant gas turbines and nuclear reactors.

* Information listed above is at the time of submission. *

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