Multi-Principal Element Alloys for Extreme Environments

Avalanche Energy is developing a high-throughput, tailored-to-requirement process (“solution”) for discovering, developing, and deploying refractory multi-principal element alloys (MPEA) for extreme environments at scale within 12 months. The solution is designed to facilitate the rapid development of plasma-facing components (PFCs) and structural materials for the company’s compact fusion reactor. The proposed Phase II solution will adapt the non-defense commercial solution to the development of MPEAs for hypersonic leading edges, specifically for reusable hypersonic aircraft and space access vehicle applications. The solution is achieved by integrating the following critical design aspects into a single, end-to-end process: An innovative AI-supported prediction system that incorporates novel performance parameters, markers (including manufacturability), and a performance-based scoring system to accelerate material down-selection.Advanced material synthesis and characterization techniques developed by partner universities, followed by the test and evaluation of select MPEAs in both relevant and operational environments in collaboration with industry partners. An adaptive MRL assessment approach that seeks to eliminate poor MPEA candidates early in the prediction process and rapidly screen prospective MPEA candidates during development by continuously evaluating the manufacturability and scalability of each candidate as part of the down-selection process.The overall objective of the Phase II effort is to demonstrate a process for identifying and developing advanced MPEA systems that can be fielded at scale within a year of discovery. To validate the solution, at least three MPEA prototypes will be developed, tested, and qualified as TRL 6+ per the key performance parameters, including manufacturability, which will be assessed using the adaptive MRL assessment process. Each material will address one of three applications—fusion PFCs and hypersonic leading edges at Mach 5 and Mach 20+ conditions. The proposed solution addresses the following critical technology areas (CTA):Advanced Materials: Accelerates the discovery-to-deployment timeline of MPEAs, targeting the CTA’s goal of “reducing the development cycle by >100x” and supporting the Defense Industrial Base rapidly by maturing advanced materials and manufacturing capabilities. Rapidly fields MPEAs into systems at scale and reduced cost. Hypersonics: Supports CTA priorities of “demonstrating and delivering transformational capabilities through rapid design, build, test, and learn” and “reducing the cost of hypersonic systems and increasing industrial capability to build warfighting inventories” by rapidly developing and fielding MPEAs for hypersonic leading edges.Energy Resilience: Enables the development of fusion and advanced nuclear reactors via the development of materials that improve reactor performance and extend operational lifetimes.