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Completed TRL 3 (started at 2, targeting 3)
NASA missions on Mars and the Moon require materials that can perform in extreme environments. Shape memory alloys (SMAs) meet this need in solid-state actuators and advanced structural pseudoelastic applications. To fully exploit these technologies, however, SMAs need to be joined to other SMAs and conventional materials without sacrificing the high-performance nature of the material. This research features a novel approach of joining these SMAs without altering the properties of the joined materials by using gas dynamic cold spray deposition, which is a solid-state additive manufacturing (3D printing) process. Cold spray joining of SMAs will provide lighter-weight joints while maintaining robust joint integrity; thus, providing cost savings by reducing payloads.
This project looks to reduce material selection limitations and component geometry restrictions related to the joining of Shape Memory Alloys (SMAs) and other structural materials with cold spray processing. This project looks to enable impactful advancements, with long-term potential and promise, in real-time repair and component reclamation and recovery during exploratory missions. Currently, cold spray is currently used for building, reclaiming, and repairing Apache helicopter housing and driveshaft components, Boeing 747's integrated drive generators, Cu flanges, and certain types of propeller blade repair. Additionally, there are used for EMI shielding, corrosion resistant coatings, antimicrobial coatings, and DNA-based biosensors, with applications for NASA expected too.
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