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Completed TRL 4 (started at 2, targeting 4)
There are limited options for materials that can perform well at extremely high temperatures (above 2000°C). Alloys of refractory metals, e.g. tungsten, are candidates, but their properties at low temperatures make component fabrication and usage challenging. Additive manufacturing is a potential solution, but the process parameters needed to fabricate defect-free parts, as well as the effects of additive processing on material properties are not fully known. We will use computational thermodynamics calculations, machine-learning regression models, and heat transfer calculations to predict alloy behavior during processing and in-service. We will build test structures using additive manufacturing methods to assess and optimize the model predictions. The objective of this work is to develop a new refractory alloy with excellent properties at extremely high temperatures that can be successfully produced by additive manufacturing methods.
This project examines how tungsten-base alloys can have high temperature properties, but porosity and cracking occurs after additive manufacturing. Additive manufacturing enables flexibility in metal component design, but the alloys must be able to be processed by AM methods. This project will enable additive manufacturing of thin wall tungsten-base alloy components for high temperature service in NASA applications
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