Additively-Manufactured, Refractory Metal, Oxidation-Resistant (ARMOR) Alloy for High Temperature Aerospace Applications

Physical Sciences Inc. (PSI) proposes to develop and demonstrate an additively manufactured, refractory metal, oxidation resistant (ARMOR) alloy to replace the state-of-the-art Ni-based superalloys in emerging high temperature aerospace technologies. Our non-coating reliant approach will be enabled by a strategically designed refractory multi-principal element alloy (RMPEA) with a balanced chemical composition to impart inherent oxidation resistance, room temperature ductility, and high temperature strength. PSI will partner with Worcester Polytechnic Institute (WPI), who will perform high throughput computational modeling (CALPHAD and DFT) to rapidly assess and reduce the element compositional space for PSIĺs experimental development. Using our laser powder bed fusion (L-PBF) additive manufacturing system, PSI will adapt our previously developed printing parameters to fabric ARMOR alloy components with complex geometries, high resolution, and high accuracy. PSI will demonstrate that the ARMOR alloy produces a self-passivating, continuous protective scale that shields the underlying alloy material from severe oxidation when exposed to high temperature oxidizing conditions. This Phase II program will build on (1) PSIĺs prior research developing RMPEAs and high entropy materials for high temperature applications, and (2) PSIĺs prior work additively manufacturing aircraft engine components. ???????