NASA Develops 1000 Times Stronger Metal Alloy Using 3D Printing

A team of researchers at NASA has developed a new metal alloy called GRX-810, that is 1000 times stronger than any previously developed alloy. Probably even more interesting is the fact that for this project, the team of professionals relied entirely on 3D printing. To be more specific, additive manufacturing was used to uniformly disperse nanoscale oxides in the alloy, providing better thermal and mechanical properties. That results in the material having the ability to withstand temperatures up to 1,093°C (1999.4 °F) and could have a significant impact on the manufacturing of, for example, rocket engines.

The metal alloy was strengthened by oxide dispersion, a method in which small oxide particles are scattered into a metal matrix to increase its strength, heat resistance and ductility. Although NASA hasn’t revealed what metal was originally used, in most cases applying this technique, nickel or iron-aluminum alloys are used. Regarding oxide dispersion, it is also important to mention that the process is usually very time consuming and expensive. However, by relying on additive manufacturing and thermodynamic modeling, the team was able to significantly reduce time and cost, and also claims to have discovered the optimal alloy composition in just 30 simulations.

The new alloy could impact the manufacturing of some rocket parts (photo credits: NASA)

Development and Characteristics of NASA GRX-810

The researchers at NASA used very accurate computer models to determine the composition of GRX-810, particularly in terms of the amount of oxides used. They then used 3D printing to uniformly inject the nanoscale oxides. While the exact process has not been revealed by NASA, this type of dispersion allowed them to quickly and inexpensively obtain a durable alloy, that was more moldable and could withstand extreme temperatures. Its strength was also significantly increased. According to the team, GRX-810 is up to 1,000 times stronger than materials developed in the past. Dale Hopkins, deputy project manager of NASA’s Transformational Tools and Technologies project, added, “This breakthrough is revolutionary for materials development. New types of stronger and more lightweight materials play a key role as NASA aims to change the future of flight. 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.”