GRX-810 can withstand intense heat and hypersonic speeds, making it perfect for aerospace applications.
NASA has developed a new metal alloy specifically designed for use in the toughest environment of all: space. And the agency has turned to 3D printing and computer simulations to create it.
The material, named GRX-810, is an oxide dispersion strengthened (ODS) alloy that contains nanoscale oxide particles. The alloy can withstand temperatures over 2,000 degrees Fahrenheit and can last a thousand times longer than other high-performance alloys. It’s three and a half times more flexible to bend or stretch before breaking and has twice the strength to resist fracturing. It is also more malleable than existing aerospace alloys.
Not surprisingly, creating alloys like the GRX-810 is a complex and expensive process. NASA turned to computer modeling and 3D printing to help offset those challenges.
To define the composition of the alloy, agency engineers used thermodynamic modeling, which predicts energy systems combustion and alloy performance through computational thermodynamics. This modeling tool costs less than conventional trial-and-error processes and reduces time spent on dead ends by showing researchers not only what metal types to incorporate but also how much of each element to use in creating the alloy. As a result, it took only 30 simulations to determine the ideal alloy composition.
The engineers then used 3D printing to distribute nanoscale oxides throughout the material to improve its durability and high-temperature performance. Technologies such as 3D printing and electrostatic deposition make it possible to create these alloys faster and cheaper than conventional methods such as ball milling. These technologies also enable the design of ODS feedstock that performs better and gives engineers greater versatility in designing the alloys to be exactly what they need.
“Applying these two processes has drastically accelerated the rate of our materials development,” said Tim Smith, NASA material research scientist and one of the new alloy’s inventors, in a press release. “We can now produce new materials faster and with better performance than before.”
GRX-810’s properties make it a promising material for use in the aerospace industry—particularly in the production of components that will be used in high-temperature environments such as spacecraft and rocket engines. ODS alloys can tolerate much higher temperatures than other alloys before reaching their breaking point. These properties make ODS alloys quite useful for running engines hotter to boost fuel efficiency. In addition, ODS alloys can withstand atmospheric reentry forces and hypersonic speeds better than other materials.
“The nanoscale oxide particles convey the incredible performance benefits of this alloy,” said Dale Hopkins in a press release. Hopkins is a deputy project manager of NASA’s Transformational Tools and Technologies project—an initiative that researches computational and experimental tools and technologies for NASA’s aircraft development work. “This breakthrough is revolutionary for materials development.… Previously, an increase in tensile strength usually lowered a material’s ability to stretch and bend before breaking, which is why our new alloy is remarkable.”
Not only has NASA developed an innovative new material for the aerospace sector—it may also have discovered a new use for additive manufacturing technologies. While these technologies are used to design and build structures out of existing materials, NASA has demonstrated that they can also be used to develop the materials themselves.
Emerging technologies such as hypersonic vehicles need designs and materials that can withstand more and more extreme environments. NASA is turning to additive manufacturing technologies to meet those demands—and computer modeling and 3D printing promise to be critical tools in the development and production of spaceworthy materials.
