$3.6 Million Award Aims to
Revolutionize Nb-C103 Alloy for Hypersonics and Space
Applications
THOUSAND
OAKS, Calif., July 24,
2024 /PRNewswire/ -- Castheon has been selected as
the principal for the Maturing AM Technology for Nb-C103 in
Hypersonics and Space (MATCHAS) project, awarded $3.6 million. This groundbreaking initiative,
part of the America Makes program, aims to address critical
challenges in additive manufacturing (AM) by enhancing the
feedstock supply chains for Nb-C103, a high-temperature refractory
alloy crucial for hypersonic and space applications.
Traditional metal alloys used in additive manufacturing (AM) are
typically based on compositions developed for conventional
manufacturing methods. However, for critical high-temperature
applications, these traditional nickel and cobalt-based superalloys
often reach their performance limits. In contrast, refractory-based
alloys can perform at much higher temperatures, exceeding the
capabilities of traditional superalloys. This project focuses on
modifying legacy alloys or developing new ones tailored for AM to
achieve superior product performance, increased yield, improved
producibility, and reduced post-processing costs. High-value
materials like high-temperature refractory alloys and nickel-based
superalloys are at the forefront of this research.
The MATCHAS program specifically targets the cost-efficiency and
performance enhancement of Nb-C103 powder feedstock by qualifying
an extended particle size distribution (PSD) for both laser powder
bed fusion (PBF-LB) and directed energy deposition (DED) methods.
Castheon aims to utilize a larger percentage of a powder production
run, thereby reducing costs and enhancing productivity.
In collaboration with ATI, AP&C, and Amaero, Castheon will
leverage its expertise to qualify extended powder sizes from a
15-180 μm production run, ensuring material integrity and
reliability. Castheon will use these feedstocks for PBF-LB
manufacturing, while FormAlloy will handle the DED processes, both
guided by historical material performance data.
The selected final materials will undergo rigorous testing led
by NASA Glenn Research Center and NSL. Lockheed Martin and Firefly
Aerospace will serve as production transition partners, further
maturing refractory AM materials for hypersonic thermal protection
systems and space propulsion applications.
The program includes practical demonstrations to achieve direct
performance validation and aims to reach a Manufacturing Readiness
Level (MRL) of 7. Castheon aims to support the MATCHAS project's
ambitious targets, which include a 42% reduction in Nb-C103 powder
costs and a 150% increase in AM productivity, all while preserving
material properties and part performance.
A notable highlight of this program is Castheon's successful
integration of a C-103 thruster into the Firefly Spectre engine,
destined for the Blue Ghost Lunar lander. This achievement
highlights the potential of the MATCHAS program, and Castheon as
principal, to drive advancements in both hypersonic and space
exploration technologies.
Dr. Youping Gao, founder of
Castheon, shared his enthusiasm for the project: "Our expertise
with refractory alloys, particularly Nb-C103, is what sets us apart
in the industry. This project aligns closely with my passion for
solving complex challenges in metal additive manufacturing. Our
comprehensive, science-based knowledge in AM, combined with a
robust production approach, enables us to lead the industry with
state-of-the-art solutions. We have dedicated ourselves to
improving the performance and capabilities of the greater industry
through innovative AM solutions. The MATCHAS project embodies that
mission, and we are thrilled to lead this transformative
effort."
Gregory Pilon, Chief Revenue
Officer of ADDMAN Group, commented on the project's impact: "The
MATCHAS project is a significant milestone for Castheon and the
broader ADDMAN Group. By advancing Nb-C103 alloy capabilities, we
are enabling a wider range of applications in hypersonics and space
exploration. This project not only enhances our technological
leadership but also solidifies our commitment to providing
cutting-edge solutions that serve the evolving needs of our
customers and the industry."
Media Contact: Chandler Stillman;
chandler.stillman@addmangroup.com
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SOURCE ADDMAN