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Materials and Process for Additive Manufacturing of Large Diameter Hall-Effect Thrusters.

Award Information
Agency: National Aeronautics and Space Administration
Branch: N/A
Contract: 80NSSC21C0174
Agency Tracking Number: 212326
Amount: $124,992.00
Phase: Phase I
Program: SBIR
Solicitation Topic Code: Z10
Solicitation Number: SBIR_21_P1
Solicitation Year: 2021
Award Year: 2021
Award Start Date (Proposal Award Date): 2021-05-10
Award End Date (Contract End Date): 2021-11-19
Small Business Information
Erie, CO 80516-8441
United States
DUNS: 079973429
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Jeremy Iten
 (720) 545-9016
Business Contact
 Jeremy Iten
Phone: (720) 545-9016
Research Institution

Existingnbsp;magnetic materials and manufacturing methods are inadequate for producing large-diameter Hall-effect thrusters (HETs) with adequate mechanical strength while achieving the desired magnetic properties. Cobalt-ironnbsp;soft ferromagnetic alloys are desirable for soft magnetic applications, including Hall-effect thrusters, due to their unparalleled magnetic saturation, elevated permeability, high curie temperature, and extreme strength.nbsp;Unfortunately, these alloys suffer from manufacturability problems due to low ductility and an inability to produce such alloys in large form factors. While Co-Fe soft magnetic products can be readily produced in sheets, production of large billets results in weak, brittle, and inhomogeneous materialsElementumnbsp;3D is proposing to develop an additive manufacturing (AM) process and material feedstock, suitable for fabrication of large-diameter HETs, fromnbsp;cobalt-iron based soft magnetic material. The ability for AM to produce these large structures directly from powder feedstock would overcome the unavailability of sufficiently sized iron-cobalt billets. Other AM advantages for production of Co-Fe soft magnetic products include, a favorable fly-to-buy ratio, improved design freedom, and an increase in thrust-to-weight ratio.Thenbsp;principlenbsp;objective of the Phase I effortnbsp;is tonbsp;research,nbsp;develop,nbsp;and demonstratenbsp;anbsp;soft magneticnbsp;feedstock material and additive production processnbsp;that is suitable fornbsp;production of large-diameternbsp;Hall-effect thrusters,nbsp;meeting the magnetic and mechanical performance targets.nbsp;

* Information listed above is at the time of submission. *

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