The evolution of carbon nanotube composites, as inspired by the Materials Genome Initiative, unlocks new potential for materials sustainability in challenging deep space applications. This article describes research and development work at the Institute for Ultra-Strong Composites by Computational Design (US-COMP), a NASA Space Technology Research Institute consortium. US-COMP has developed a novel composite material with mechanical properties per unit mass that exceed state-of-the-art structural composites.

During the 20th century, the use of aluminum alloys helped the Allied Powers win World War II and made modern global air travel possible. Continuous improvements in engine technology, alloys, and manufacturing methods enabled the development of practical and efficient aircraft with varying passenger capacity and range capability. Conventional wrought aluminum alloys make up 70-80% of the weight of single-aisle airliners. Aluminum sheet, plate, forgings, extrusions, and castings all continue to be utilized in modern aircraft construction. This article explores a brief history of the special alloys, tempers, and product forms required to meet the unique challenges of flight.

The extreme high-speed laser application (EHLA) process offers efficient deposition of high-performance materials in aerospace manufacturing, providing key advantages compared to conventional laser cladding. As a sustainable alternative to chrome plating, EHLA excels in material integrity, efficiency, and performance, while reducing costs compared to thermal spray and conventional laser cladding. This article discusses how EHLA can help to address many sustainability concerns within the manufacturing sector.

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.

Molybdenum aluminum boride (MAB) phases have layered nanolaminate structures, suiting them for potential use in cutting tools, leading edges for hypersonic vehicles, high-temperature electrodes, and other demanding applications. This case study demonstrates a process for the production of MoAlB particulates and their incorporation in polymer-matrix composites.

Among the structural materials developed in the 20th century, titanium and its alloys have played a leading role in improving component performance. This article discusses development of new production techniques, specifications, economic aspects, and applications that have enabled the current applications of titanium alloys.

Among the structural materials developed in the 20th century, titanium and its alloys have played a leading role in improving component performance. This article provides background on the extraction and primary processing of titanium.

The Nadcap accreditation process ensures that manufacturers performing heat treating and other special processes adhere to consistent, high-quality standards. This final article in the series looks at the official audit process, auditor interactions, and completing the official audit.

Aerospace Material Specification (AMS) standards and Nadcap (National Aerospace and Defense Contractors Accreditation Program) play key roles in ensuring that manufacturers performing heat treating and other special processes adhere to consistent, high-quality standards for producing aerospace products. This is the first in a series of articles that break down the process of obtaining Nadcap accreditation for a heat treating facility.

Field assisted sintering technology (FAST) enables hybrid components for aerospace to be designed with reduced weight and without sacrificing performance. FAST can be used to produce metal, ceramic, and composite components with tailored properties via a powder metallurgy approach. In many cases, it is a one-step, cost-effective manufacturing process for production of net-shape components.

Titanium's potential was not fully realized until 1956 when metal production reached 5200 tons and sponge production nearly 15,000 tons. After a decade of difficult R&D and an investment of several hundred million dollars by government and industry, titanium fulfilled its promise as a new metal for jet engine and airframe applications.

The titanium industry was launched in the 1950s and required the efforts of numerous metallurgical engineers and research laboratories, nearly a dozen corporations, and titanium metal producers, along with hundreds of millions of dollars.

The only process available for producing titanium was patented by William J. Kroll in 1940, marking the dawn of a new metals industry.

Integrated computational materials engineering has proven effective in shrinking materials development timelines and accelerating the implementation of new materials in manufactured components. This article presents examples of aerospace alloys developed using ICME techniques and provides a glimpse of future applications.

This article presents an overview of the use of thermal spray technology at The Boeing Co., dating back to 1968 when the first thermal spray specification, "Plasma Flame Spray Coating," was released. It also discusses anticipated needs based on industry trends.