I-Corps: Translation potential of a lightweight, high-temperature alloy optimized for three-dimensional (3D) printing

This I-Corps project is based on the development of a lightweight, high-temperature metal alloy designed to prevent hazardous space debris from satellites that reenter the atmosphere and fail to fully burn up. Satellite designers currently avoid titanium for larger components to prevent this hazard, relying instead on aluminum, which requires more material and added weight to match titanium's strength. Satellite manufacturers face growing pressure to reduce weight and cost while meeting tightening safety requirements. This technology provides a new alloy combining titanium-level strength with substantially lower cost and a lower melting point, allowing it to fully burn up during reentry rather than persist as debris or create projectile hazards. This technology may reduce material and transportation costs across aerospace, transportation, and other manufacturing sectors that rely on strong, lightweight materials, and may reduce the risk of hazardous space debris. This I-Corps project utilizes experiential learning coupled with first-hand investigation of the industry ecosystem to assess the translation potential of an intermetallic alloy. This alloy exhibits a theoretical density of approximately 4.1 g/cm³, an estimated tensile strength exceeding 1,500 MPa, and a melting point between 800 and 1000°C, together yielding titanium-class specific strength while relying on earth-abundant, low-cost elements. Satellite manufacturers currently cannot use titanium for structural components of 1 kilogram or larger because titanium's high melting point prevents it from fully burning up during reentry in earth's atmosphere, creating atmospheric debris. The current workaround, aluminum, requires greater mass and volume to match titanium's strength. Prior research established the alloy's crystal structure, mapped its compositional stability window, and identified pathways to broaden its narrow processability range. Due to its lower melting point, the alloy is designed to ablate and fully burn up during the deorbiting of a decommissioned satellite. This alloy may serve as a material alternative when mass reduction and satellite reentry compliance are required. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.