Don't worry. I'm not going to talk about nu metal or Limp Bizkit! I’m here to introduce you to some important new metals from the always-riveting world of material science. So, let’s get rollin’, rollin’, rollin’.
Evolutional Alloys
Back when I learned y’all on Inconel and its heat and corrosion-resistant properties – and how it was difficult to process before additive manufacturing – I also talked about its predecessor, Monel, which was used for U.S. military dog tags until it was replaced by T304 stainless steel.
My point is: There’s always going to be something newer and hotter. Alloys are constantly evolving to meet new demands and incorporate the latest developments. New technologies can even create new possibilities for old(er) materials – like additive manufacturing and Inconel.
AerMet
OK, bear with me: I’m going to talk a little about guns. Specifically, firearm bolts, which are like vault doors for a gun’s chamber; they keep all the pressure from the deflagrating propellants from going the wrong way. They are tasked with being near-immovable objects to contain that pressure, as well as being able to move with minimal resistance when called upon. They need to be made from some pretty incredible material!
Bolts for the M4/M16-based rifles used by U.S. Special Operations Command used to be made out of Carpenter 158 steel, which dunks on common 300-series stainless steel. However, such “secretive” weapons often utilize suppressors (aka silencers), which work like car mufflers: they keep things quiet(er). They also have similar drawbacks – but of a multiplied magnitude.
Any gearhead can tell you that standard mufflers build too much back pressure and rob cars of precious power. Suppressors on automatic weapons generate an astronomical amount of back pressure (which yields a higher cyclic rate of fire and thus accelerate wear and tear) that most guns – especially the M4/M16 – were not designed to handle. This led to a lot of broken bolts. That’s not a good thing during covert operations. Enter AerMet 100.
Admittedly, AerMet 100 isn’t new. Conceived in the ‘80s by Carpenter, the AerMet family of alloys was originally used for other high-speed, low-drag Department of Defense applications. It was in things like landing gear for military aircraft and high-stress components in the catapult launching systems of aircraft carriers. The bolts didn’t come around until the mid-2000s, and they’ve never been classified as “mil-spec” because, well, covert. So, while AerMet isn’t as old as Inconel, it’s still older than I am.
Disclaimer: I’m not a paid shill for Carpenter – just an enthusiastic material science dilettante. In fact, there is a far superior – and cheaper – alloy to Carpenter 158 – and it’s older than Inconel!
The steel alloy 9310 has a nearly identical composition to Carpenter 158 but includes molybdenum. This makes it much easier to harden – and far less expensive since it does not require any of Carpenter’s proprietary and costly preparation. The downside is that some alternative surface treatments and coatings can ruin the hardening. But it has a pedigree as bolt material for many dependable, modern, fully automatic weapon systems. And once you get a government contract, you’re made in the shade of a flourishing money tree
The Next Level: What’s NASA doing?
So, what’s actually new? GRX-810. You’ve probably heard it mentioned in manufacturing news here and there over the past few years, and it’s new enough that there’s not a whole lot of easily accessible information yet. Try Googling “GRX-810.” I’ll wait.
Not easy, huh?
If you’re like me and your results showed a bunch of bicycle parts, add “alloy” to your search. That’ll get you to some articles about NASA letting four companies validate the claims of how special GRX-810 is. One of those companies is Elementum 3D, where some personal material science heroes of mine work, and another is one you may recognize: Carpenter. What a coincidence!
What do we know about GRX-810 so far? It’s an incredibly durable, nickel-based, oxide dispersion-strengthened (ODS) alloy that’s easier to 3D print than alloys with less (or no) nickel. With a refractory metal-rich composition, it withstands temperatures of over 2,000 F (1,093 C) and is twice as strong and oxidation-resistant as existing alloys. Using computational modeling and 3D printing, stable oxide particles are incorporated throughout its metal matrix, enhancing high-temperature performance – perfect for extreme aerospace conditions. It’s seemingly an insane leap forward in specialty alloy material science!
Please Wrap This Up
And there you have it! Whether it's for keeping our covert operatives in action with stealthy tech or helping NASA reach new heights (literally), the future of metals and material science is evolving faster than ever. Keep your eye on GRX-810 – it might just be the next game changer. Until then, stay sharp, stay curious, and remember to put “alloy” in your Google search strings!
To read the rest of the Industry Outlook Issue of MT Magazine, click here.
