Powderloop joins ESA-backed initiative to develop metal AM powders for space applications
Powderloop Technology Limited, headquartered in Braintree, UK, has joined TWI Ltd, Cosmic Bridge Ltd and Bearingline in the European Space Agency’s ‘Prepare for Space’ initiative. With its in-situ alloying technology, Powderloop is looking to bring its powder manufacturing technology and hard-facing powders into the space industry, enhancing sustainability and supply-chain resilience in the sector.
The Prepare for Space programme will provide a targeted market analysis of advanced coatings applied via Additive Manufacturing and thermal spraying for space applications, strengthen the business case for deployment of the technology in relevant space applications, and identify and develop commercial opportunities within the European and international space supply chain.
TWI Ltd, as the ESA technology Broker for the UK will work alongside Cosmic Bridge Ltd to provide a materials and market opportunity assessment followed by use-case definition and opportunity framing. Following this, coating implementation feasibility using the selected powder will be conducted by TWI, ahead of commercial direction assistance courtesy of Bearingline.
Powderloop’s in-situ alloying involves the formation of a micro-scale carbide directly in the melt pool during the Additive Manufacturing process. The evenly distributed, homogeneous carbide precipitates enhance the material hardness, fracture toughness and corrosion resistance, protecting components used in extreme environments such as those encountered by the space sector.
The company’s spherical, free-flowing powders are produced by agglomerating fine elemental and/or master-alloy particles into composite granules, allowing a wide range of materials to be used, including refractory metals (tungsten, tantalum, niobium, titanium), hardmetals (tungsten carbide), and cermets (titanium carbide).
The cobalt-free, tungsten-titanium-based, multi-carbide powder produced by Powderloop is currently at technology readiness level (TRL) 3/4. The inclusion of a nickel or iron-rich matrix reduces the amount of tungsten carbide required. Through the Prepare for Space programme, Powderloop aims to coat test coupons and components with the new powder and evaluate their performance for space applications, with the intention of advancing the technology from TRL3/4 to TRL6.
According to Powderloop, the powder is suitable for use with a range of Additive Manufacturing processes, including Directed Energy Deposition (DED), Extreme High-Speed Laser Material Deposition (EHLA) and Laser Beam Powder Bed Fusion (PBF-LB).
Potential applications are said to include wear-resistant tools, robotic joints for lunar and Martian exploration, where components must withstand the high-abrasive regolith processing. It may also be suitable for applications such as propulsion, thruster nozzles, or for repairing high-value spacecraft components that require resistance to wear, corrosion, and high temperature stability.
