GRX-810 for Cold Spray Additive Manufacturing, Coating, and Repair

The goal of the proposed Phase I project is to understand and evaluate the feasibility of processing GRX-810 material by cold spray through systematic spray trials on both bulk and single particle scales. Elementum 3D, the project lead, has a co-exclusive commercial license for GRX-810 production and to our knowledge is currently the only licensee capable of successfully blending the yttrium oxide nanoparticles with base alloy powder at large scales (10-100 kg per batch) relevant for industrial processing needs. Elementum 3D will use their large capacity, high energy blending process to provide feedstock powder for bulk and single particle cold spray experiments for this effort. Bulk spray studies will be carried out using semi- and fully-robotic cold spray systems at Penn State University's Applied Research Laboratory, while single particle impact studies will be performed at the University of Utah on a Laser Induced Particle Impact Testing (LIPIT) system. Adhesion characteristics of uncoated base alloy and coated GRX-810 finished material will be compared to assess the effects of the nano-yttria coating. Blends of various particle size distributions and oxide loading will be evaluated to assess the impact of each on bulk deposition or coating. For each spray trial resulting in successful deposition, characterization via SEM, EDS, EBSD, and/or optical metallography will be performed, and high density samples will be further subjected to hot isostatic pressing to maximize density and assess any changes in microstructure or oxide distribution. The findings will be compiled in a final report. Should Phase I prove successful, Phase II work will focus on optimizing the cold spray process and characterizing the thermal and mechanical characteristics (up to 1300 deg C) of GRX-810 in bulk and coated forms.