QuesTek’s ICMD® software platform digital enables digital transformation for materials engineering and the development of novel materials. (Image courtesy QuesTek Innovations/PRNewswire)
QuesTek’s nickel-based superalloy is critical for an engine that demands materials capable of withstanding extreme combustion environments.
EVANSTON, Ill.—QuesTek Innovations reported that it successfully developed a novel nickel-based superalloy designed for additive manufacturing and extreme aerospace environments.
The development is said to mark a critical milestone in the company’s collaboration with Stoke Space, a pioneering OEM developing reusable rockets designed to fly daily. Their mission is to enable high-performance, fully reusable launch systems with dramatically lower cost and higher launch frequency, according to a release from QuesTek Innovations.
The alloy—engineered to withstand high-pressure, high-temperature oxygen environments—has been fully qualified and meets all performance targets. It is described as critical for Stoke Space’s cutting-edge Zenith engine. The engine operates using a full-flow staged combustion cycle, a high-efficiency system that demands materials capable of withstanding extreme combustion environments where conventional alloys would catastrophically fail, the release stated.
QuesTek designed the alloy using its ICMD® digital materials design and engineering platform. The use of ICMD enabled rapid optimization of composition and processing within months—a process that traditionally would take years, if not decades, the company said in the release.
“The development of this printable, burn-resistant alloy is an absolute requirement for Stoke Space to achieve its mission of building reusable rockets that fly daily,” said Jason Sebastian, executive vice president of QuesTek, in the release. “It’s not an overstatement to say that this type of milestone can change the world. Once this hurdle is removed, I don’t see a limit to the growth potential for the space industry.”
The nickel-based superalloys QuesTek has developed for Stoke Space are production-printable via additive manufacturing, which enables complex geometries and cooling channels that would not be possible with traditional manufacturing. Leveraging printability also allows for rapid implementation of design changes without the lead time and expense of producing new tooling, according to QuesTek.
“The material compositions commonly used to increase strength often reduce printability and burn resistance,” said Bill Mahoney, chief operating officer at QuesTek, in the release. “QuesTek technology helps clients find their sweet spot where all three critical properties coexist—something that would take traditional metallurgy approaches decades to develop. We achieved it in just months.”
According to QuesTek, its partnership with Stoke Space has shown what’s possible when digital materials design meets next-generation aerospace needs.
“From propulsion systems to thermal protection and structural components, and to micro-power systems, QuesTek’s Materials by Design® and ICMD® technologies can help unlock new solutions across the space sector, accelerating the path to routine, affordable access to orbit and beyond,” the release stated.