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The GRCop story: The development, production and Additive Manufacturing of NASA's rocket engine alloys The new space race is powered by metal Additive Manufacturing. In turn, the Additive Manufacturing of rocket engines is powered by advanced alloys. Of these, NASA's GRCop family has found use in numerous critical applications. In this article, Austin Whitt and David Ellis, NASA Glenn Research Center, and Paul Gradl, NASA Marshall Space Flight Center, dig deep into the history, production, processing and maturation of these unique materials. As the authors reveal, there is good reason why Additive Manufacturing of GRCop begins by understanding the process-microstructure-property-performance relationship.
The aerospace industry is truly remarkable and, all too often, we take its astonishing achievements for granted. The seamless connectivity of the internet, GPS, cellular phones, and telecommunications systems are all made possible by the intricate array of satellites launched aboard powerful rockets. In the vast expanse of space, the International Space Station tirelessly orbits 400 kilometres above Earth, pushing the boundaries of scientific discovery. We marvel at high-speed aircraft executing manoeuvres that test the limits of human endurance. We gaze in awe at the captivating images beamed back from rovers exploring Mars and deep-space telescopes venturing into the farthest reaches of distant galaxies. This industry not only enhances our daily lives with materials, electronics, and technological advancements, but also shows us the grandeur of our universe. What is truly striking is the common thread that runs through all these incredible projects: a vision of the future and an immense team effort, often involving thousands,
Vol. 9 No. 4 © 2023 Inovar Communications Ltd
if not tens of thousands of individuals working together to achieve the extraordinary. In the aerospace world, it's a rarity to single out one person for credit on a project, as the magnitude of these accomplishments necessitates the collective expertise and collaboration of countless dedi-
cated individuals. However, within this collective endeavour, people like Dr David Ellis from NASA Glenn Research Center in Cleveland, Ohio, stand out. Dr Ellis is a materials researcher and an expert on high thermal conductivity materials for rocket engines. Dr Ellis’ career work
Fig. 1 Hot-fire test of a PBF-LB GRCop-42 plug nozzle and outer body for a Rotating Detonation Rocket Engine (Courtesy NASA)
Metal Additive Manufacturing | Winter 2023
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The GRCop story
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