Additively Manufactured Oxide Dispersion Strengthened Steel for Nuclear and High-Temperature Applications

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. Advanced nuclear energy systems require materials that endure extreme temperatures and intense radiation while maintaining structural integrity. Oxide dispersion strengthened (ODS) steels incorporate nanoscale ceramic particles to enhance high-temperature mechanical properties and radiation tolerance, making them ideal for these demanding environments. However, traditional ODS steel manufacturing relies on mechanical alloying that deforms powder particles during additive manufacturing processes. This incompatibility with modern manufacturing methods has severely limited the applicability of ODS steels in next-generation nuclear systems. In response to this issue, engineers at NASA Glenn Research Center developed Additively Manufactured Oxide Dispersion Strengthened Steel for Nuclear and High-Temperature Applications. This invention coats iron-chromium steel powder with yttria nanoparticles while preserving the flowability needed for additive manufacturing, producing high-strength, radiation-resistant components with design flexibility for nuclear applications.