https://www.nasa.gov/image-feature/nasas-new-3d-printed-superalloy-can-take-the-heatNASA has demonstrated a breakthrough in 3D printable high-temperature materials that could lead to stronger, more durable parts for airplanes and spacecraft.
A team of innovators from NASA and The Ohio State University detailed the characteristics of the new alloy, GRX-810, in a peer-reviewed paper published in the journal Nature.
“This superalloy has the potential to dramatically improve the strength and toughness of components and parts used in aviation and space exploration,” said Dr. Tim Smith of NASA’s Glenn Research Center in Cleveland, lead author of the Nature paper. Smith and his Glenn colleague Christopher Kantzos invented GRX-810.
GRX-810 is an oxide dispersion strengthened alloy. In other words, tiny particles containing oxygen atoms spread throughout the alloy enhance its strength. Such alloys are excellent candidates to build aerospace parts for high-temperature applications, like those inside aircraft and rocket engines, because they can withstand harsher conditions before reaching their breaking points.
Current state-of-the-art 3D printed superalloys can withstand temperatures up to 2,000 degrees Fahrenheit. Compared to those, GRX-810 is twice as strong, over 1,000 times more durable, and twice as resistant to oxidation.
Ref 22: https://journals.aps.org/prl/pdf/10.1103/PhysRevLett.116.135504Overcoming the strength–ductility trade-off is a result of atomic-scale deformation mechanisms16, such as locally variable stacking-fault energies19 and magnetically driven phase transformations20. This class of alloys has also proven to be robust, resisting hydrogen environment embrittlement21, exhibiting improved irradiation properties22 and providing superior strength at cryogenic temperatures23.
https://www.space.com/us-economy-nasa-3d-printed-superalloyAs of now, the superalloy is licensed to four American companies; going forward, it could result in positive commercial dividends, NASA says, and benefit the overall U.S. economy.
The four companies selected are Carpenter Technology Corporation of Reading, Pennsylvania, Elementum 3D, Inc. of Erie, Colorado, Linde Advanced Material Technologies, Inc. of Indianapolis, and Powder Alloy Corporation of Loveland, Ohio.
GRX-810 was originally developed with aerospace equipment in mind, including liquid rocket engine injectors, combustors, turbines and hot-section components capable of enduring temperatures over 2,000 degrees Fahrenheit (1,093 degrees Celsius), according to a NASA release. The brains behind the superalloy are Tim Smith and Christopher Kantzos, both researchers at NASA Glenn. They say the design was drafted up by pairing computer modeling with a laser 3D-printing process to meld together, layer-by-layer, the metals involved.
GRX-810 is an advanced multi-principal element alloy (MPEA) that is designed to exhibit superior mechanical properties, corrosion resistance, and thermal stability. It is composed of multiple principal elements, which allows it to achieve a unique combination of strength and ductility compared to traditional alloys.
GRX-810 is primarily used in industries that require high-performance materials, such as aerospace, automotive, and energy sectors. Its excellent mechanical properties make it suitable for components that must withstand extreme conditions, including high temperatures and corrosive environments.
Compared to traditional alloys, GRX-810 offers enhanced mechanical properties, including improved strength-to-weight ratios and better resistance to fatigue and wear. The multi-principal element design allows for a more uniform microstructure, which contributes to its superior performance in demanding applications.
The benefits of using MPEAs like GRX-810 include improved mechanical properties, greater design flexibility, and enhanced performance in extreme environments. The ability to tailor the composition of MPEAs allows for the optimization of specific characteristics required for various applications.
While GRX-810 offers many advantages, challenges include the complexity of its manufacturing processes and potential difficulties in achieving consistent quality and performance. Additionally, the cost of raw materials and processing can be higher compared to conventional alloys, which may limit its widespread adoption.