Novel Single-Phase Refractory-Metal Alloy for Reusable Thermal Protection Systems

NASA wants to support the formation of a sustainable Low Earth Orbit economy, which requires the development of lower-cost, readily-available, robust, and reusable Thermal Protection System (TPS) solutions. Precision Materials Engineering LLC (PRIME) proposes to leverage the ground-breaking research being performed at Ames National Laboratory in the field of high-temperature refractory-materials, including: 1) Fundamental-physics-based materials modeling, 2) Ultrasonic-atomization powder production, and 3) Novel additive manufacturing (AM). Their work has produced a unique single-phase refractory-metal alloy that offers an unparalleled combination of properties; high melting temperature (~2200C), high strength (1 GPa (145 ksi)), high ductility (>25%), and formability (60% rolling reduction)/weldability. Proposed research by PRIME to advance the TRL of this material includes fabrication of material coupons at Ames to measure thermophysical properties (by outside vendors), application of oxidation-protective coatings (by pack-cementation (Ames) and high-voltage plasma-electrolytic-oxidation anodize (PRIME)), screening high-temperature oxygen-acetylene plasma testing (PRIME), and AM demonstration of arc-jet test articles (Ames). Key plans for Phase II include: 1) Hot-rolling reduction of the new refractory-metal alloy to representative acreage TPS facesheet thickness, 2) Concepts for man-made orbital debris mitigation such as AM methods to add geometry on the vehicle-side TPS facesheet, and 3) Simulated re-entry testing in an arc-jet environment. Candidate applications include: 1) Nose-cones, wing leading-edges, and acreage TPS facesheets for reusable space and hypersonic vehicles / weapons, 2) Cladding materials for valve and pump parts (or entire parts by AM) for molten-salt nuclear reactors (MSR), 3) Components used in waste-to-energy conversion systems, 3) Components used in transportation-engine exhaust systems, and 4) Components for gas-turbine engines.

Demonstration of this new single-phase refractory-metal alloy will have application for NASA space vehicles (leading-edge components, acreage-area TPS facesheets, propulsion-system components) to ensure lower-cost, readily-available, robust, and reusable access to space. By demonstrating oxidation-protection coatings, including separate pack cementation and plasma-electrolytic-oxidation anodize methods, adherent, protective oxides will be formed that reduce oxygen diffusion into the underlying refractory-metal alloy substrate. These protective surfaces will require less person-hours of refurbishment which reduces maintenance costs and increases access to space. Furthermore, by incorporating structural geometry on the facesheet inner surfaces by AM processing (Phase II), man-made-orbital debris will be disrupted, increasing survivability. Non-NASA commercial applications for this new single-phase refractory-metal alloy include: 1) Hypersonic vehicles / weapon systems for DoD applications. Components include: engine nozzles, pintles, nose tips, leading edges, control surfaces; 2) Molten-salt nuclear reactor (MSR) components for molten-salt valve and pumps, including claddings of current stainless steel parts and eventually AM-fabrication of entire parts and even valve bodies; 3) Components used in waste-to-energy conversion systems, including claddings for boiler-system tubing or drawing of tubing from the refractory-metal alloy; 4) Components used in transportation-system engine exhaust systems; 5) Gas-turbine engine hot-section components, blades, vanes, and blisks; 6) Cutting tools for hard-to machine materials; and 7) Medical devices.

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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