Solid-State Cold Spray Additive Manufacturing (CSAM) of GRX-810

New propulsion and vehicle concepts continue to push the boundaries of material performance at extreme environments. Traditional materials and alloys have struggled to meet these new demands, however, a promising new class of alloys has been developed which combines multi- principal element alloys (MPEAs) with dispersion strengthening (DS). Uniquely amenable to additive manufacturing (AM), these alloys can produce incredible elevated temperature performance relative to incumbent Ni-superalloys. However, thus far, their fabrication has largely been limited to laser powder bed fusion (L-PBF), which is generally not scalable to the demands of large propulsion and vehicle concepts, while other melt-based modalities struggle to attain the performance of L-PBF due to slower quench rates. Therefore, this work proposes utilization of a novel solid-state thermal-spray based manufacturing method: cold spray additive manufacturing (CSAM). This method overcomes the scaling limitations of L-PBF to enable buildup of large components at economically feasible rates, ameliorates quenching challenges by never melting, provides the capability for coatings and repair work, and potentially enables a faster route to new alloy development.