Development of Nickel-Titanium Graded Composition Components

The potential of various manufacturing methods was evaluated for producing nickel-titanium graded composition material. The selected test case examined attachment brackets that join nickel-based metallic thermal protection systems to titanium-based launch vehicle structure. The proposed application would replace nickel-based components with graded composition components in an effort to alleviate service induced thermal stresses. Demonstration samples were produced by laser direct metal deposition, flat wire welding, and ultrasonic consolidation. Microstructure, general bond quality, and chemistry were evaluated for the components.