NASA and The Ohio State University have created a brand-new metal called GRX-810, a printable superalloy engineered to withstand extreme heat inside jet and rocket engines. It is being called one of the most significant breakthroughs in high-temperature materials in recent years. NASA says GRX-810 is twice as strong as the best 3D printed superalloys available today, more than a thousand times more durable at high temperatures, and twice as resistant to oxidation. The team demonstrated it using laser 3D printing and believes it could lead to stronger and longer-lasting parts for airplanes, spacecraft, and high-performance engines.

GRX-810 is what materials scientists refer to as an oxide dispersion strengthened alloy. In essence, it is a nickel, cobalt, and chromium-based metal reinforced with tiny ceramic particles. These nano-oxides, specifically yttrium oxide (Y₂O₃), make up about one percent of the alloy by weight. NASA coats the metal powder with these nanoscale oxides before printing, and then fuses the powder together layer by layer using laser powder bed fusion.

As the part solidifies, the oxide particles remain locked inside the metal matrix like rebar in concrete. This reinforcement stops the metal from deforming or cracking when exposed to both high heat and heavy load. The alloy’s recipe involves nine different metallic elements along with the nano-oxides, and this combination was optimized through computational alloy design rather than trial and error.