Solid-State Cold Spray Additive Manufacturing (CSAM) of GRX-810 (CSAM)

New propulsion and vehicle concepts continue to push the boundaries of material performance at extreme environments. Traditional materials and alloys have struggled to meet these new demands, however, a promising new class of alloys has been developed which combines multi- principal element alloys (MPEAs) with dispersion strengthening (DS). Uniquely amenable to additive manufacturing (AM), these alloys can produce incredible elevated temperature performance relative to incumbent Ni-superalloys. However, thus far, their fabrication has largely been limited to laser powder bed fusion (L-PBF), which is generally not scalable to the demands of large propulsion and vehicle concepts, while other melt-based modalities struggle to attain the performance of L-PBF due to slower quench rates. Therefore, this work proposes utilization of a novel solid-state thermal-spray based manufacturing method: cold spray additive manufacturing (CSAM). This method overcomes the scaling limitations of L-PBF to enable buildup of large components at economically feasible rates, ameliorates quenching challenges by never melting, provides the capability for coatings and repair work, and potentially enables a faster route to new alloy development.

The proposed work could benefit a number of NASA applications and directorates, including the Aeronautics Research Mission Directorate (ARMD): Transformational Tools and Technologies, the ARMD: Hypersonics Technology Project, the Space Technology Mission Directorate (STMD): Nuclear Thermal Propulsion, the SMTD: Game Changing Development (Optimized and Repeatable Components in Additive-manufacturing [ORCA], Rotating Detonation Rocket Engine [EDRE]). Each of these directorates and technology spaces could benefit from near net shape production of high end alloys, particularly those such as the oxide dispersion strengthened alloy in the proposed work. There are a number of applications for this technology outside of NASA. First is the aerospace propulsion market, wherein high temperature capable, oxidation and creep resistant dispersion strengthened alloys could be utilized in rocket engines, gas turbine engines, rotating detonation engines, space nuclear propulsion concepts, and RAMJET and SCRAMJET concepts. The HAMR team also works in the hypersonics space, where thermal protection systems could likewise benefit from these properties and the potential tailorability of the approach. Another large application space is for nuclear applications, where dispersion strengthened materials are considered likely candidates for next-generation plant concepts, however, the manufacturing and scalability has been limited. Solving these challenges in the proposed work would enable a new paradigm and adoption. Finally, lightweight alloys for the automotive and aerospace markets could also be explored by likewise strengthening and stabilizing novel Mg, Al, and lightweight HEAs.

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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