Castheon will use its expertise with refractory alloys and improving material properties to advance the capabilities of Nb-C103 alloy. (Image courtesy ADDMAN Group/PRNewswire)
Castheon was selected as principal for the MATCHAS project, seeking to ‘revolutionize’ the alloy for hypersonics and space applications.
THOUSAND OAKS, Calif.—Castheon, an ADDMAN Group company, was selected as the principal for an America Makes project that was recently awarded $3.6 million in funding to support efforts to “revolutionize Nb-C103 alloy for hypersonics and space applications,” according to a release from the ADDMAN Group.
The America Makes project, “Maturing AM Technology for Nb-C103 in Hypersonics and Space (MATCHAS),” aims to address critical challenges in additive manufacturing (AM) by enhancing feedstock supply chains for Nb-C103, a high-temperature refractory alloy crucial for hypersonics and space applications.
America Makes is an association of “members from industry, academia, government, and workforce and economic development organizations” that “work together to accelerate the adoption of additive manufacturing and the nation’s global economic competitiveness,” the organization’s website stated.
Based in Youngstown, Ohio, America Makes was founded in 2012 as the U.S. Department of Defense’s national manufacturing innovation institute for additive manufacturing and the first of the Manufacturing USA network. It is managed by the not-for-profit National Center for Defense Manufacturing and Machining (NCDMM).
Castheon said in the release that traditional metal alloys used in additive manufacturing are typically based on compositions developed for conventional manufacturing methods. For critical high-temperature applications, however, 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.
The MATCHAS project focuses on modifying legacy alloys or developing new alloys tailored for additive manufacturing 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, according to the release.
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 laser powder bed fusion (PBF-LB) and directed energy deposition (DED) methods. Castheon is aiming to use 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 additive manufacturing materials for hypersonic thermal protection systems and space propulsion applications.
The program, which includes practical demonstrations to achieve direct performance validation, aims to reach a Manufacturing Readiness Level (MRL) of 7. Castheon is working to support the MATCHAS project’s ambitious targets, which include a 42 percent reduction in Nb-C103 powder costs and a 150 percent increase in additive manufacturing productivity—all while preserving material properties and part performance, the release said.
A notable highlight of the 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 is said to highlight the potential of the MATCHAS program, and of Castheon as principal, to drive advancements in hypersonic and space exploration technologies.
Castheon Founder Youping Gao, Ph.D., shared his enthusiasm for the project.
“Our expertise with refractory alloys, particularly Nb-C103, is what sets us apart in the industry,” Gao said in the release. “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.”
ADDMAN Group Chief Revenue Officer Gregory Pilon commented on the project’s impact.
“The MATCHAS project is a significant milestone for Castheon and the broader ADDMAN Group,” Pilon said in the release. “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.”