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<p>There is a trade-off in nickel-based superalloys between burn resistance in a high-pressure oxygen combustion environment and strength. High-performance, closed-cycle rocket engines use high-pressure liquid oxygen (LOX) which can create a combustion reaction when exposed to common commercially available high-strength nickel alloys. In the interest of minimizing weight and maximizing thrust of rockets, a high-strength, burn-resistant nickel-based superalloy is ideal. This is especially important for reusable rockets, where the degradation of materials must be minimized to reduce the need to replace components between launches and the relatively lower operating temperature of a full-flow staged-combustion engines enabled in part by&#xa0;LOX-compatible materials can significantly improve thermal fatigue and creep life. Additionally, with the recent progress toward industrialization of space travel, there are more rocket manufacturers than ever, and there is a need for flexible, fast, and supply chain resilient manufacturing paths such as additive manufacturing. With known trade-offs between printability, high-pressure oxygen burn resistance, and high strength for nickel-based superalloys due to a propensity for strain-age cracking in precipitation-strengthened alloys, the three objectives of high strength, printability, and burn resistance result in a complex alloy design scenario. Using the ICMD<sup>®</sup> Software Platform, novel alloys are rapidly designed by co-optimizing these three key properties with physics-based integrated computational materials engineering (ICME) modeling.</p>

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Using ICME to Design a Novel High-Strength, Printable, and Burn-Resistant Nickel-Based Superalloy for Reusable Rocket Engines

  • 期刊论文

  • 发表日期：

    2026年7月7日

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  • Gary F. Whelan,
  • Abhinav Saboo

摘要

There is a trade-off in nickel-based superalloys between burn resistance in a high-pressure oxygen combustion environment and strength. High-performance, closed-cycle rocket engines use high-pressure liquid oxygen (LOX) which can create a combustion reaction when exposed to common commercially available high-strength nickel alloys. In the interest of minimizing weight and maximizing thrust of rockets, a high-strength, burn-resistant nickel-based superalloy is ideal. This is especially important for reusable rockets, where the degradation of materials must be minimized to reduce the need to replace components between launches and the relatively lower operating temperature of a full-flow staged-combustion engines enabled in part by LOX-compatible materials can significantly improve thermal fatigue and creep life. Additionally, with the recent progress toward industrialization of space travel, there are more rocket manufacturers than ever, and there is a need for flexible, fast, and supply chain resilient manufacturing paths such as additive manufacturing. With known trade-offs between printability, high-pressure oxygen burn resistance, and high strength for nickel-based superalloys due to a propensity for strain-age cracking in precipitation-strengthened alloys, the three objectives of high strength, printability, and burn resistance result in a complex alloy design scenario. Using the ICMD® Software Platform, novel alloys are rapidly designed by co-optimizing these three key properties with physics-based integrated computational materials engineering (ICME) modeling.