MORE | Fall 2025

Additive Manufacturing of FeCrAl + TiC Composite for High-Temperature Applications

FeCrAl alloys are promising for high-temperature uses, like nuclear fuel cladding and gas turbines, due to their oxidation and corrosion resistance, but conventional processing limits strength and geometry. This study uses laser powder bed fusion to fabricate FeCrAl reinforced with TiC nanoparticles, addressing issues of coarse TiC precipitates. Rapid solidification in AM promotes fine, thermally stable precipitates; varying scan speed controls TiC size and distribution. The research tests whether 5 wt.% TiC addition enhances 500 °C strength and if higher scan speeds refine microstructure. SEM and tensile tests will reveal strengthening behavior, supporting sustainable, durable alloy development for extreme environments.