Additive Manufacture of Refractory Alloy C103 for Propulsion Applications

C103 is niobium alloy used in high temperature operating environments. Traditional manufacture methods suffer from feedstock constraints, difficult to machine, high buy-to-fly ratios, and high costs resulting in a limited number of suppliers. Additive manufacture (AM) offers advantages in production of complex parts, improved properties, reproducibility, with significant material cost and schedule savings. The objectives of this project was to investigate the feasibility to AM C103, develop powder feedstock, optimize process parameters, establish design criteria, investigate post-process heat treatments, and determine material properties. AM C103 proved feasible, increased design flexibility, improved mechanical properties compared to wrought, and resulted in an order of magnitude cost reduction.