NASA licenses 3D-printable superalloy that’s 2,500x stronger

Visualizing a more durable and longer-lasting aircraft and spacecraft that could resist exorbitantly high temperatures has been an aspiration of aerospace industries for a long time.

Now, a team of engineers and researchers at NASA devised a 3D-printed superalloy called GRX-810 specifically for aerospace applications. 

A research team led by Dr. Tim Smith and Christopher Kantzos at NASA’s Glenn Research Center claims the alloy demonstrates exceptional durability and strength, withstanding temperatures exceeding 2,000 degrees Fahrenheit and lasting up to 2,500 times longer than traditional alloys. 

Material shows precise composition and microstructure control

To adapt to the rapidly advancing laser 3D-printing technology, NASA developed a material exhibiting precise composition and microstructure control, making it different from conventional approaches. 

The superalloy has been enhanced with resistance to oxidation damage and top-notch performance characteristics, promising to revolutionize aerospace technology for longer-lasting and more efficient aircraft and spacecraft components.

Nasa says that GRX-810 is designed for extreme temperatures and harsh conditions of air and spaceflight. The 3D-printable high-temperature material enhances durability and strength, making it suitable for aerospace applications such as liquid rocket engine injectors, combustors, turbines, and hot-section components.

“GRX-810 represents a new alloy design space and manufacturing technique that was impossible a few years ago,” noted Dr. Tim Smith, materials researcher at NASA Glenn.

Computer model and laser 3D printing fused to form superalloy

Smith alongside Christopher Kantzos, a colleague at Glenn deployed a time-saving computer modeling and laser 3D-printing method combing metals together layer by layer. The strength-improving element is due to the tiny particles comprising oxygen atoms that spread throughout the alloy.

Now the space agency is licensing its technology to four American firms which will allow the latter to manufacture and market GRX-810 to airplane and rocket equipment manufacturers and also the complete supply chain.

NASA’s four co-exclusive licensees are with–Carpenter Technology Corporation of Reading, Pennsylvania, Elementum 3D, Inc. of Erie, Colorado, Linde Advanced Material Technologies, Inc. of Indianapolis, Powder Alloy Corporation of Loveland, Ohio. 

“NASA invests tax dollars into research that demonstrates direct benefit to the U.S. and transfers its technologies to industry by licensing its patents,” stated Amy Hiltabidel, licensing manager at NASA’s Glenn Research Center in Cleveland.

“Adoption of this alloy will lead to more sustainable aviation and space exploration,” stated Dale Hopkins, deputy project manager of NASA’s Transformational Tools and Technologies project. 

“This is because the jet engine and rocket components made from GRX-810 will lower operating costs by lasting longer and improving overall fuel efficiency.”

Teams from Glenn, NASA’s Ames Research Center, The Ohio State University, and NASA’s Marshall Space Flight Center conducted recent testing involving the 3D-printed rocket engine parts with the new material.

The statement by NASA noted that patent licensing and other mechanisms allow the agency to spin off more than 2,000 technologies for companies to develop into products and solutions supporting the American economy.