GRX-810 for Cold Spray Additive Manufacturing, Coating, and Repair

The goal of the proposed Phase I project is to understand and evaluate the feasibility of processing GRX-810 material by cold spray through systematic spray trials on both bulk and single particle scales. Elementum 3D, the project lead, has a co-exclusive commercial license for GRX-810 production and to our knowledge is currently the only licensee capable of successfully blending the yttrium oxide nanoparticles with base alloy powder at large scales (10-100 kg per batch) relevant for industrial processing needs. Elementum 3D will use their large capacity, high energy blending process to provide feedstock powder for bulk and single particle cold spray experiments for this effort. Bulk spray studies will be carried out using semi- and fully-robotic cold spray systems at Penn State University's Applied Research Laboratory, while single particle impact studies will be performed at the University of Utah on a Laser Induced Particle Impact Testing (LIPIT) system. Adhesion characteristics of uncoated base alloy and coated GRX-810 finished material will be compared to assess the effects of the nano-yttria coating. Blends of various particle size distributions and oxide loading will be evaluated to assess the impact of each on bulk deposition or coating. For each spray trial resulting in successful deposition, characterization via SEM, EDS, EBSD, and/or optical metallography will be performed, and high density samples will be further subjected to hot isostatic pressing to maximize density and assess any changes in microstructure or oxide distribution. The findings will be compiled in a final report. Should Phase I prove successful, Phase II work will focus on optimizing the cold spray process and characterizing the thermal and mechanical characteristics (up to 1300 deg C) of GRX-810 in bulk and coated forms. GRX-810 is a new oxide dispersion-strengthened nickel superalloy material with exceptional high temperature properties. It was developed primarily for laser powder bed fusion (PBF-LB) processing, which is best suited for low-rate fabrication of relatively small components with high geometric complexity. Cold spray processing of GRX-810 could expand its application space due to its potential to increase build rate by up to 50x relative to PBF-LB, its very large (~1 cubic meter build envelope) component fabrication capability, the ability to repair worn or damaged GRX-810 components, and the ability to coat GRX-810 on a different component bulk material. Because the material is still new and its commercial supply is limited to just four co-licensees -- of which only Elementum 3D has demonstrated large scale high energy blending capability -- the deposition behavior of GRX-810 under cold spray conditions has not yet been investigated or reported. To expand the application space and market for GRX-810, Elementum 3D is leading this proof-of-concept effort for GRX-810 in cold spray.

NASA GRC materials scientist and GRX-810 inventor Tim Smith and NASA MSFC additive manufacturing expert Paul Gradl have publicly put forth the following NASA applications for GRX-810 material: liquid rocket engine components, various injectors, channel-cooled nozzles, rotating detonation rocket engines, and lander development engines. Successful bulk cold spray additive manufacturing of GRX-810 will enable larger scale, faster additive manufacturing of similar components than is readily achievable with the established laser powder bed fusion process. Moreover, bulk cold spray methods can be used for repair of worn or damaged GRX-810 components to enhance component lifetime and reuse capability. Coatings can be used to confer GRX-810 hardness, corrosion/oxidation resistance, and wear resistance properties to the surface of a component with a different bulk composition and properties -- such as copper alloys -- for applications such as combustion chamber liners, as in NASA's Low Cost Upper Stage-Class Propulsion project. Cold spray of GRX-810 for non-NASA applications is likely to be primarily beneficial for aerospace, defense, and oil and gas industry applications. In aerospace and defense, cold spray deposited oxidation and wear resistant GRX-810 coatings may be used for the development of new, lightweight, high efficiency turbine engine components such as multi-material heat tiles. Moreover, repair of coated components or bulk GRX-810 components can be accomplished on-location using VRC Systems' and SPEE3D's equipment specifically targeted toward in-field manufacturing and repair. These capabilities are also attractive for oil and gas companies that maintain drilling equipment in remote locations. Drill pipes, drill bits, downhole tools and tubing, wellhead components, and pumps and valves are all application areas for nickel superalloys in oil and gas that would benefit from bulk GRX-810 or coatings of the same.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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