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Shape memory alloys (SMAs) are metals that can return to their original shape following thermal input. They are commonly used as functional materials in sensors, actuators, clamping fixtures and release mechanisms across industries. SMAs can suffer from dimensional/thermal instability, creep, and/or low hardness, resulting in alloys with little to no work output in the long term. To combat these deficiencies, NASA has developed a process of incorporating nanoparticles of refractory materials (i.e., carbide, oxide, and nitride materials with high temperature resistance) into the alloys. Using various processing methods, the nanoparticles can be effectively mixed and dispersed into the metal alloys as shown in the figure below. In these processes the SMA and refractory material powder is mixed and the refractory nanoparticles incorporated through extrusions, melting, or directly used in additive manufacturing to create parts for applications across the aerospace, automotive, marine, or biomedical sectors. The nanoparticle dispersion is a controllable method to strengthen the SMAs, increasing the hardness of the alloys, reducing the impact of creep, and improving the overall dimensional and thermal stability of the alloys. The related patent is now available to license. Please note that NASA does not manufacture products itself for commercial sale.

Dispersion Enhanced Aluminum Alloys improve the additive manufacturing performance of high-strength aluminum alloys by modifying the alloy powder with uniformly dispersed nano-sized ceramic particles. Building on the dispersion and acoustic mixing methods developed during the creation of NASA Glenn's GRX-810 technology, researchers use an acoustic field to attach nanoscale alumina dispersoids to the surface of each aluminum alloy powder particle. During mixing, acoustic energy creates rapid micro-vibrations that cause the alumina particles to collide with the metal powder, embed against its surface, and distribute into a uniform shell that surrounds each particle. This produces a composite powder in which every aluminum particle carries its own evenly spaced ceramic nucleation sites. When the composite powder is delivered into an additive manufacturing process such as laser powder bed fusion or directed energy deposition, the aluminum alloy melts while the alumina dispersoids remain solid due to their significantly higher melting temperature. As the molten pool flows and mixes, the dispersoids remain suspended throughout the liquid region. During solidification, these solid particles interrupt grain growth and serve as nucleation points that promote the formation of fine equiaxed grains. This refined microstructure distributes thermal stresses more uniformly and disrupts the crack initiation mechanisms that typically occur in high-strength alloys like AA 2050. By stabilizing the alloy during solidification, the technology enables these advanced materials to be printed with greater reliability, improved geometric control, and more consistent mechanical behavior across the final product. The enhanced alloy technology is available for patent licensing.