Until now, additive manufacturing, commonly known as 3D printing, of engine components was limited by the lack of affordable metal alloys that could withstand the extreme temperatures of spaceflight.
Until now, additive manufacturing, commonly known as 3D printing, of engine components was limited by the lack of affordable metal alloys that could withstand the extreme temperatures of spaceflight. Expensive metal alloys were the only option for 3D printing engine parts until NASA’s Glenn Research Center in Cleveland, Ohio, developed the GRX-810 alloy.
The primary metals in the GRX-810 alloy include nickel, cobalt, and chromium. A ceramic oxide coating on the powdered metal particles increases its heat resistance and improves performance. Known as oxide dispersion strengthened (ODS) alloys, these powders were challenging to manufacture at a reasonable cost when the project started.
However, the advanced dispersion coating technique developed at Glenn employs resonant acoustic mixing. Rapid vibration is applied to a container filled with the metal powder and nano-oxide particles. The vibration evenly coats each metal particle with the oxide, making them inseparable. Even if a manufactured part is ground down to powder and reused, the next component will have the qualities of ODS.
The benefits over common alloys are significant – GRX-10 could last up to a year at 2,000°F under stress loads that would crack any other affordable alloy within hours. Additionally, 3D printing parts using GRX-810 enables more complex shapes compared to metal parts manufactured with traditional methods.
Read More: National Aeronautics and Space Administration (NASA)
Image: GRX-810 is a new metal alloy developed by NASA for 3D printing parts that can withstand the extreme temperatures of rocket engines, allowing affordable printing of high-heat parts. (Credit: NASA)
