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Building on the dispersion and acoustic mixing methods developed during the creation of NASA's Glenn Research Center GRX-810 technology, this Additively Manufactured ODS Steel uses an innovative coating process to overcome the limitations of traditional ODS steel manufacturing. The technology deposits yttrium oxide nanoparticles onto spherical iron-chromium steel powder particles. During the additive manufacturing process, the coated powder particles are melted and consolidated layer by layer using laser powder bed fusion. As the material solidifies, the oxide nanoparticles distribute uniformly throughout the microstructure, creating a dispersion-strengthened material. The dispersed yttria nanoparticles pin grain boundaries and dislocations, significantly improving creep resistance and mechanical strength at elevated temperatures. Preliminary testing has demonstrated a 10-fold improvement in creep properties compared to non-ODS baseline steels. The technology demonstrates compatibility with industrial-scale laser powder bed fusion systems and can be adapted to incorporate alternative ceramic nanoparticles beyond yttria. Applications span the nuclear energy sector, including commercial fission reactor components, fusion reactor first-wall and blanket structures, nuclear thermal propulsion systems for space exploration, and in-space nuclear power systems where extreme temperature performance and radiation resistance are essential. This strengthened steel is available for patent licensing.

The advent of additive manufacturing makes available new and innovative integrated thermal management systems, including integrating an oscillating Heat Pipe (OHP) into the leading edge of a hypersonic vehicle for rapid dissipation of large quantities of heat. OHPs have interconnected capillary channels filled with a working fluid that forms a train of liquid plugs and vapor bubbles to facilitate rapid heat transfer. Multiple additive manufacturing techniques may be used, including powder bed fusion, binder jetting, metal material extrusion, directed energy deposit, sheet lamination, ultrasonic, and electrochemical techniques. These high performance OHPs can be made with materials such as Refractory High Entropy Alloys (RHEAs) that can withstand high temperature applications. The structure of the OHP can be integrated into the constructed leading edge. The benefits include a heat transport capacity of 10 to 100 times greater than before. Integrated OHPs avoid the bends or welds in traditional heat pipes, especially at the locations where the highest thermal stresses might cause thermal-structural failure of a leading edge. Alternating the diameters of the OHP channels alleviate start-up issues typically found in liquid metal oscillating heat pipe designs in high temperature applications by aiding in the instigation of a circulating flow due to multiple forces acting upon the working fluid.