Multi-Principal Element Alloys for Extreme Environments

Avalanche Energy will invent and commercialize a novel, dual-use, end-to-end process (i.e., from design through manufacturing) for developing refractory MPEAs with novel nanostructure coatings. MPEAs are candidate materials for protecting hypersonic and fusion systems under extreme operating conditions, being designed to withstand thermal stresses up to at least ~1800 °C. The process will consist of computation/design, synthesis, characterization, and manufacturing. The design process will involve the use of existing first-principles methodologies enhanced by novel AI-powered tools. Samples will be synthesized using various experimental techniques (e.g., arc melting, additive manufacturing) and characterized via microstructural, chemical, tensile, and irradiation testing. Down-selected alloys will be then be exposed to further examined in relevant operational environments. Next, the manufacturing process will be developed by scaling bulk synthesis methods. Once the basis MPEA is synthesized, a separate novel nanostructure system will be developed and layered on top of the basis MPEA. The purpose of the nanostructure system is to provide a thermal protection barrier against high-heat fluxes for hypersonic weapons or act as a defect sink for fusion reactor applications. Finally, advanced oxide coatings that protect hypersonic leading edges against oxidation-induced damage will be developed as well as the process for applying the coating to bulk materials. The goal of this project is to create a complete process for developing extreme-performance MPEAs for nearly any application with a consistent degree of quality and reliability.