Low Cost HIP Fabrication of Advanced Power Cycle Components and PM/Wrought Inconel 740H Weld Development (Final Technical Report)

The objective of this Phase 1 project is to demonstrate the feasibility of structures and components for advanced fossil energy power cycle by fusion welding powder metallurgy (PM) based near net shape (NNS) hot isostatic pressing (HIP) Nickel superalloy Inconel 740H (IN740H) components to wrought IN740H components. The outcome of the project includes a prototype pipe elbow demonstration of the NNS HIP process using IN740H powder, an initial assessment of IN740H PM/wrought weldability, and a manufacturing and capital cost analysis of IN740H NNS HIP components for advanced ultra-super critical steam (AUSC) power plants. The anticipated value proposition of NNS HIP manufacturing is ~50% cost reduction of large complex components in AUSC or super-critical carbon dioxide (sCO2) power cycles. This document is a final technical report for the project, covering efforts conducted from October 2019 to June 2021.