Powder bed fusion of solid and permeable Crofer 22 APU parts for applications in chemical process engineering

Additive manufacturing of metals has attracted significant attention across various industries. However, its adoption in certain chemical and energy sectors remains constrained by the absence of optimized alloys tailored for high temperatures and corrosive environments. This study explores the laser-based powder bed fusion processing of Crofer 22 APU, a high-temperature, corrosion-resistant alloy ideal for applications such as methane steam reforming reactors, high-temperature fuel cells, and palladium membrane supports. Systematic optimization of laser parameters including laser power, hatch distance, point distance, and building angles was conducted for both dense and porous objects. Dense parts achieved a relative density of 0.9999 and surface roughness of Sa= 41.27±1.48 on a 45 \(^\circ\) $_{}^{\circ }$ overhang. Porous samples showed a porosity range of 28.6 to 55.5% and surface roughness Sa 22.2  \(\upmu\) $\mathrm{\mu }$ m to 45.9  \(\upmu\) $\mathrm{\mu }$ m as hatch distance increased from 0.12 mm to 0.16 mm. Additionally, an 8YSZ coating applied via screen printing demonstrated the impact of hatch distance and laser power on surface quality. The combination of additive manufacturing of Crofer 22 APU and screen printing of 8YSZ simplifies the preparation of metallic supports for Pd-based membranes, reducing fabrication time and cost by shortening the number of preparation steps. This technique offers a promising approach for scaling up membranes and membrane reactors.