Laser powder bed fusion (LBFP) additive manufacturing is a potential route for the rapid qualification of new materials for use in nuclear reactor design. Process anomalies such as spatter particles can induce lack of fusion (LOF) voids that may adversely affect the material's mechanical performance. This examination of the spatter particle process in a nickel superalloy using X-ray computed tomography and optical microscopy was conducted to identify possible causes for the formation of LOF voids and other variations during LBPF processing.

NASA developed a novel oxide dispersion strengthened (ODS) NiCoCr-based alloy, GRX-810, that exhibits exceptional high temperature properties compared to conventional wrought superalloys for 3D printing applications. In this interview, the co-inventors, Tim Smith and Christopher Kantzos, discuss the alloy's unique development process and its superior high strength and durability for aerospace and other extreme conditions.

A look at Monel after decades of exposure to the environment shows more work is needed to address the lack of scientific research and information in the conservation literature. Three case studies are presented related to the analysis of Monel artifacts.

Case studies from a range of industries illustrate how advanced additive manufacturing capabilities optimize both material performance and value. The materials discussed are Inconel 718, Ti-6Al-4V, aluminum F357, and Hastelloy X.

Monel 400 was used as a decorative building material from 1905 to the mid-1930s, when it was replaced by stainless steel. This article discusses the development and commercialization of this short-lived architectural metal, also known as nickel alloy 400.

A novel framework including experimental and model-based techniques saves time and enables the introduction of new alloys for additive manufacturing. This article describes the first phase of the probabilistic machine learning framework that was successfully demonstrated to rapidly define optimum parameter sets for commercial high-temperature nickel superalloys, as well as to guide alloy design and selection for compatibility with laser powder bed fusion additive manufacturing.

Hot section components of next-generation energy systems call for superalloys that can handle the heat. This article describes some recent advances in superalloy research and development, including characterization and modeling tools that are key to developing and understanding the formation of new superalloys capable of withstanding extreme environments.

For parts made by direct metal laser melting, heat treatment is important to set the final microstructure, which impacts mechanical properties.

New thermal and cold spray technologies are being developed to extend the lifespan of thermal barrier coating (TBC) systems at elevated temperatures. This article describes the relevant attributes of coating technologies such as high velocity air fuel, high velocity air plasma spray, and high pressure cold spray for use in TBC systems.

Boronizing 3D-printed Inconel 718 for improved wear resistance produces results similar to those obtained for wrought 718.

Recent advances in neutron sources and detector technologies enable new contrast mechanisms to determine crystalline information for metal components. This new capability can help validate emerging additive manufacturing processes used to produce parts with complex geometries.

Vacuum heat treating is a crucial step in the additive manufacturing process cycle to meet required part quality specifications.

Orion’s Exploration Flight Test 1 vehicle used four additively manufactured vent assemblies to equalize pressure between unpressurized portions of the spacecraft and the external environment.

Oxide dispersion strengthened (ODS) alloys have potential to improve turbine blade temperature capability beyond that of superalloy single crystals. In this article, the case is made for the potential to replace single crystals as high-pressure turbine blades with ODS nickel-base alloys. ODS alloys combine proven technology, substantial gains in capability over today’s single crystal alloys, and a clear development path to overcome identified risks.

Vacuum plasma and low pressure plasma spray technologies each provide unique solutions for achieving superior properties in metallic coatings that require low oxide content and high density. Applications include various turbine engine components, as well as biomedical and electronics components.

Renewed interest in a NASA-developed material known as Triboglide has led to a study of the friction and wear properties of HVOF-sprayed Triboglide coatings and close variants. This article describes the coating process, examines coating cross-sections, and presents and analyzes the results of high-temperature pin-on-disc wear tests.

This article discusses the development and use of a nondestructive evaluation (NDE) method that allows researchers to compare surface crystallographic orientations before and after mechanical testing to determine the impact of surface orientation on material response. Two gage samples were tested, one rectangular (Ti-Al), the other round (IN100). The samples were placed in a SEM equipped with an EBSD detector and a motorized fixture that rotates the test piece as EBSD and imaging data are collected. Inverse pole figure maps of both gage samples are presented.

Thermal spray coatings are widely used to keep power plants running at full capacity. An example is the application of HVOF-sprayed CrC-NiCr to protect generating and superheater banks from sulfuric and vanadium gases. Other examples include the use of arc spraying to deposit high Cr content Ni alloy to extend the life of coal-fired boiler tubes and to apply amorphous work hardening coatings to surfaces in the flu gas path that are susceptible to high-temperature corrosion and wear.