Modeling the Mechanical Behavior of GRX-810: a High-Performance Material for Extreme Aerospace Applications

GRX-810 is a promising new NASA-developed metal alloy that is manufactured through a 3D metal printing process with oxide dispersion-strengthening. Experiments have shown that this material is able to withstand extremely high temperatures of over 2000 degrees fahrenheit and can provide over a 1000-fold increase in creep resistance compared to commonly used polycrystalline wrought Ni-based alloys [1], making it an exciting candidate for usage in aerospace parts subject to extreme temperatures and loading conditions such as rocket engines and turbine blades. This study proposes a comprehensive computational modeling project focused on the mechanical behavior of GRX-810 with three key components: developing a material model to characterize the performance of the metal, modeling long-term creep behavior under sustained stress, and examining material behavior during the manufacturing process via 3D metal printing. As a preliminary process, the General Viscoplasticity with Potential Structure (GVIPS) model [2] will be implemented in code to reproduce known results for classical materials such as the TIMETAL 21S titanium alloy [3]. Once this model is confirmed to reproduce accurate results, GVIPS can then be used as a foundation to develop the viscoplastic material model for GRX-810, which will allow for characterization of essential material properties such as strength, ductility, hardness, toughness, and fatigue resistance. This newly created model will be validated with physical experiments performed using uniaxial and multiaxial loading, hardness, Charpy, and monotonic and cyclic loading tests. Then, creep behavior describing gradual time-dependent deformation of GRX-810 under constant stress will be modeled. This is a critical property of the material, given its application in high-temperature environments with long-term loading; the developed model characterizing creep will be able to predict potential material failures of structures utilizing GRX-810 at large time scales, and will also enable the exploration of methods to enhance creep resistance through optimized manufacturing techniques. Lastly, the comprehensive material model for GRX-810 will be implemented into simulations of the 3D metal printing process with incorporated heat effects, and material behavior under extremely concentrated thermal loading will be examined to gain insights on material yielding and plastic deformation during manufacturing. The effects of different laser scanning speeds, paths, and temperatures on stress evolution and material deformation can be investigated, which will enable optimization of these critical manufacturing parameters to minimize material defects and enhance resulting material performance. Through this comprehensive approach, this project not only advances the understanding and application of GRX-810 but also establishes a versatile framework for characterizing and optimizing the manufacturing processes and material properties of future groundbreaking materials designed for extreme aerospace conditions.

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