Gas turbines operate under extreme heat and stress. As gas turbine industry moves toward hydrogen-fueled systems, components must withstand even higher temperatures. Additive manufacturing enables smarter designs to meet these demands, but printing high-performance metals is still challenging. Ahmed Fardan Jabir Hussain, Doctoral Student at Chalmers University of Technology, is tackling this challenge to make 3D printing viable for the toughest applications.
Additive manufacturing (3D printing) enables intricate designs, such as cooling channels inside turbine blades, which enables higher operating temperature inside the turbine which is essential for improving the gas turbine efficiency. But when it comes to high-performance metals, the process of printing is complex. One such metal is CM247LC which is exceptionally durable and ideal for applications in extreme environments, but also one of the hardest metals to process with 3D printing.
“The superalloy is often called “the Holy Grail” of metal additive manufacturing. If we can process it successfully, it could enable higher operating temperatures and improve efficiency of industrial gas turbines,” says Ahmed Fardan Jabir Hussain.
The alloy tends to crack either during printing or in post-processing heat treatment and has limited resistance to deformation under long-term high temperatures (known as creep) compared with cast components, issues that make it unsuitable for industrial use in its current printed form.
Finding solutions through process optimization
Rather than altering the alloy itself, Fardan focused on getting the most out of the existing standard composition. By fine-tuning laser power, scanning strategies, and heat treatments, he reduced cracking and significantly improved durability. These efforts resulted in nearly crack-free samples in simple geometries such as cubes, however the cracking during post-processing heat treatment in complex geometries remains. Additionally, his research also indicates how to print and heat treat CM247LC to improve creep performance.
“One of the biggest lessons through this work is that you can’t just fix one problem in isolation. If you reduce micro-cracking too much, you might worsen macro-cracking or creep performance. A holistic approach is essential. That’s where collaboration with industry really helps.”
Industrial benefits
Throughout his PhD, Fardan collaborated closely with Siemens Energy. Håkan Brodin, Materials Technology Expert at Siemens Energy, highlights the impact of this collaboration.
“Fardan’s research has given us valuable insights into how to process these challenging materials. We’re already applying the learnings to develop new alloys and improve our additive manufacturing processes,” says Håkan Brodin.
He also emphasizes why this matters for industry.
“We’ve reached the limits with traditional materials and cooling strategies. To go further, we need better materials and processes, and this research helps us do exactly that,” says Håkan Brodin.
Wider application
The ability to reliably print high-temperature turbine components could transform energy production by enabling higher efficiency, reduced emissions, and more flexible supply chains. But the methods and insights from this research also have wider application.
“Even if this material in particular remains difficult, the lessons we’ve learned can definitely be applied to other superalloys and help advance additive manufacturing as a whole,” says Ahmed Fardan Jabir Hussain.
Ahmed Fardan defends his PhD thesis on 16 December 2025
Read the thesis and see the time and location of the defense.
- Doctoral Student, Materials and Manufacture, Industrial and Materials Science