The University of Utah, Penn State, and Elementum 3D have secured a NASA STTR Phase I grant to investigate the cold spray additive manufacturing of GRX-810, an oxide dispersion-strengthened alloy. The 13-month research project aims to map the bonding physics of this high-temperature material, with Elementum 3D providing feedstock and manufacturing expertise. Dr. Suhas Eswarappa Prameela of the University of Utah STARS Lab will utilize a Laser-Induced Particle Impact Test system to isolate variables such as particle velocity and surface condition, while Penn State leads the cold spray process development. This collaboration seeks to bridge the gap between fundamental material science and the practical requirements for reusable rocket engine components.

Cold spray additive manufacturing offers a high-deposition-rate alternative to traditional DED or LPBF processes for large-scale aerospace structures, but the bonding behavior of complex alloys like GRX-810 remains poorly characterized. By isolating single-particle impact dynamics, this study addresses a critical technical bottleneck in certifying additively manufactured parts for extreme-environment propulsion systems. As NASA continues to push for reusable launch vehicles, the ability to reliably print high-performance, heat-resistant materials is essential for reducing production lead times and material waste in the aerospace supply chain.

This research provides the empirical data required to transition GRX-810 from laboratory-scale testing to industrial-scale cold spray production. The project partners must now successfully correlate single-particle impact data with bulk deposition properties to prove the viability of the process for flight-critical hardware. Buyers and manufacturers should focus on the resulting process parameters, as these will define the feasibility of using cold spray for complex, high-temperature engine geometries in future aerospace programs.