Advancements in AM with NASA’s GRX-810 Alloy

A new alloy developed by NASA for AM parts that can withstand extreme temperatures of rocket engines.

Until recently, additive manufacturing (AM) materials faced significant hurdles in producing engine components for spaceflight. The primary limitation was the lack of affordable metal alloys capable of withstanding the extreme temperatures encountered during space missions. Traditionally, only expensive alloys were viable for engine parts—until NASA’s Glenn Research Center in Cleveland, Ohio, introduced the groundbreaking GRX-810 alloy.

The GRX-810 alloy is composed of nickel, cobalt, and chromium, enhanced by a ceramic oxide coating that increases heat resistance and overall performance. This coating is part of what makes GRX-810 an oxide dispersion strengthened (ODS) alloy. Initially, manufacturing these powders at a reasonable cost presented challenges. However, NASA developed an innovative dispersion coating technique using resonant acoustic mixing. This method applies rapid vibrations to a mixture of metal powder and nano-oxide particles, ensuring that each metal particle is uniformly coated, creating a robust and inseparable composite. Even when ground down for reuse, the properties of ODS remain intact in subsequent components.

The advantages of GRX-810 over conventional alloys are striking. It can endure stress loads at temperatures around 1,090 °C (2,000 °F) for an entire year—far exceeding the lifespan of typical alloys, which can fail within hours under similar conditions. Using AM allows for the creation of complex shapes that are difficult to achieve using traditional manufacturing methods.

Commercial space ventures and industries like aviation are exploring the alloy's potential in various applications, including flow sensors that monitor gas speeds in turbines. These sensors are critical for optimizing engine performance but often fail under extreme temperatures. Utilizing GRX-810 could significantly enhance fuel efficiency while reducing emissions and maintenance costs.

Through these advancements, NASA is not only pushing the boundaries of space technology but also fostering growth in America’s expanding space interests.