Development of a Novel Process for Refractory Metal Powder Production

NASA seeks high-quality pre-alloyed metal powders for advanced additive manufacturing (AM), particularly refractory metals. These metals are vital for high-temperature propulsion components with a broad range of applications, ranging from advanced chemical rockets to nuclear thermal and electric propulsion. These refractory metals are used to make parts from liquid rocket engine chambers to thrusters for OMVs. This project aims to develop an industrial-scale process for synthesizing refractory metal powder. It will establish scaling laws for the process as well as parameters to control particle size distribution, critical for high-quality parts manufactured through AM processes like laser powder bed fusion (L-PBF). This innovative method reduces impurities, conserves energy, and yields spherical particles ideal for L-PBF. It also supports the development of new alloys through AM, enhancing the sustainability of pre-alloyed refractory metal powder sources.

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