Advanced Alloy for High Temperature Applications - Snippet from NASA findings

NASA and The Ohio State University have created a novel superalloy that exhibits double the strength, over 1,000 times the durability, and twice the oxidation resistance of current advanced 3D printed superalloys. The innovation may result in enhanced and more resilient components for aircraft and spacecraft, as the high-temperature alloy is an ideal candidate for manufacturing aerospace parts intended for high-temperature environments, such as those within aircraft and rocket engines, owing to its capacity to endure more extreme conditions prior to failure.

Source: NASA/Jordan Salkin

There are various classes of high-temperature alloys compatible with additive manufacturing (AM). We can class them as:

·???????? Refractory metals

·???????? Carbon-carbon?composites CMC’s

·???????? Ni-base superalloys

·???????? Oxide dispersion-strengthened (ODS) alloys

One of the most spectacular examples is the Oxide Dispersion-Strengthened (ODS) alloy. However, it has been a challenge to produce ODS alloys through conventional manufacturing methods, and that is where additive manufacturing comes into play.

Scatter plot confirms the successful production of a ODS alloys using AM

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Capabilities of this superalloy

Capable of enduring temperatures up to 2,000°F, this new alloy has twice the fracture resistance, three and a half times the flexibility, and more than 1,000 times the durability compared to current materials. GRX-810's exceptional properties allow for stronger, lighter designs, reducing fuel consumption and maintenance costs in aerospace applications.

The alloy's rapid development was driven by combining thermodynamic modeling with AM accelerating the traditional trial-and-error process. The NASA team identified the optimal composition in just 30 simulations, showcasing how modern tools can shorten material discovery timelines to weeks or months.

Implication and Benefits

These alloys have major implications for the future of sustainable flight. For example, when used in a jet engine, the alloy’s higher temperature and increased durability capability translates into reduced fuel burn and lower operating and maintenance costs. This alloy also affords engine part designers new flexibilities like lighter materials paired with vast performance improvements. Designers can now contemplate tradeoffs they couldn’t consider before, without sacrificing performance.

References:

NASA’s Super Alloy: A Breakthrough in 3D Printing Technology (scitechdaily.com)

NASA’s New Material Built to Withstand Extreme Conditions - NASA

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