Novel Single-Phase Refractory-Metal Alloy for Reusable Thermal Protection Systems

NASA wants to support the formation of a sustainable Low Earth Orbit economy, which requires the development of lower-cost, readily-available, robust, and reusable Thermal Protection System (TPS) solutions. Precision Materials Engineering LLC (PRIME) proposes to leverage the ground-breaking research being performed at Ames National Laboratory in the field of high-temperature refractory-materials, including: 1) Fundamental-physics-based materials modeling, 2) Ultrasonic-atomization powder production, and 3) Novel additive manufacturing (AM). Their work has produced a unique single-phase refractory-metal alloy that offers an unparalleled combination of properties; high melting temperature (~2200C), high strength (1 GPa (145 ksi)), high ductility (>25%), and formability (60% rolling reduction)/weldability. Proposed research by PRIME to advance the TRL of this material includes fabrication of material coupons at Ames to measure thermophysical properties (by outside vendors), application of oxidation-protective coatings (by pack-cementation (Ames) and high-voltage plasma-electrolytic-oxidation anodize (PRIME)), screening high-temperature oxygen-acetylene plasma testing (PRIME), and AM demonstration of arc-jet test articles (Ames). Key plans for Phase II include: 1) Hot-rolling reduction of the new refractory-metal alloy to representative acreage TPS facesheet thickness, 2) Concepts for man-made orbital debris mitigation such as AM methods to add geometry on the vehicle-side TPS facesheet, and 3) Simulated re-entry testing in an arc-jet environment. Candidate applications include: 1) Nose-cones, wing leading-edges, and acreage TPS facesheets for reusable space and hypersonic vehicles / weapons, 2) Cladding materials for valve and pump parts (or entire parts by AM) for molten-salt nuclear reactors (MSR), 3) Components used in waste-to-energy conversion systems, 3) Components used in transportation-engine exhaust systems, and 4) Components for gas-turbine engines.