Key Takeaways
- Nasa’s Glenn Research Center developed GRX-810 alloy, a groundbreaking material for 3D printing engine components.
- The GRX-810 alloy significantly outperforms traditional alloys, resisting extreme temperatures and offering enhanced durability.
Innovative Alloy Developments
Additive manufacturing, commonly known as 3D printing, has long faced limitations in producing engine components due to the scarcity of affordable metal alloys capable of withstanding the extreme temperatures associated with spaceflight. The introduction of NASA’s GRX-810 alloy marks a revolutionary advancement in this field.
The GRX-810 alloy is comprised primarily of nickel, cobalt, and chromium, enhanced by a special ceramic oxide coating. This coating is known for increasing heat resistance and overall performance. Dubbed oxide dispersion strengthened (ODS) alloys, these materials presented manufacturing challenges that inhibited cost efficiency until now.
The innovation lies in the advanced dispersion coating technique pioneered at NASA Glenn Research Center, which utilizes resonant acoustic mixing. This process involves subjecting a mixture of metal powder and nano-oxide particles to rapid vibration, ensuring a uniform coating that binds the particles together. Consequently, even when the alloy is ground down and reused, the resulting components retain the advantageous properties characteristic of ODS.
The GRX-810 alloy boasts impressive durability, capable of enduring stress loads and persistently withstanding temperatures of up to 2,000°F for as long as a year—a performance that far exceeds that of conventional alloys, which might fail under such conditions in mere hours. Moreover, the flexible nature of 3D printing with GRX-810 facilitates the creation of more intricate designs than traditional metal manufacturing allows.
Elementum 3D, situated in Erie, Colorado, has secured a co-exclusive license for the NASA-patented GRX-810 alloy and its production techniques. The company is capable of producing GRX-810 in various batch sizes, accommodating both small-scale needs and larger industrial requirements. They collaborate closely with NASA under a Space Act Agreement to refine the alloy further.
Jeremy Iten, the chief technical officer at Elementum 3D, emphasizes the remarkable lifespan of the GRX-810 alloy: “Initial tests done on the large-scale production of our GRX-810 alloy showed a lifespan that’s twice as long as the small-batch material initially produced, and those were already fantastic.”
Industries beyond aerospace, including aviation, are currently exploring additional applications for the GRX-810 alloy. A notable example is Vectoflow, a customer of Elementum 3D, which is currently testing a GRX-810 flow sensor. Designed to monitor the speed of gases within turbines, these sensors traditionally suffer from rapid failures due to extreme thermal environments. Utilizing GRX-810 for flow sensors could significantly enhance airplane fuel efficiency while simultaneously reducing emissions and the frequency of hardware replacements.
In partnering with industry leaders, NASA is committed to propelling technology advancements beneficial to both the agency and the burgeoning American space economy. Further information can be found on NASA’s Spinoff page.
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