BlueStar proposes a novel approach to increasing thermal conductivity of commercial structural alloys for Hypersonics using AM techniques and mixed powder feeds. The idea is to maintain high temperature strength in the alloys while increasing thermal conductivity, reducing CTE to increase functionality of the alloys in thermal protection systems (TPS). Our approach will be beneficial for small production run for close to net shape parts for improved TLP components and additionally for liquid rocket motor throats and nozzles and thermal management for environment control. Plasma transfer Arc (PTA) free form fabrication based AM will be used to demonstrate use of the process Potential NASA Applications (Limit 1500 characters, approximately 150 words) The proposed innovation for improved thermal conductivity commercial alloys, will have applications for all HX and thermal control systems for manned spaceflight. Additonal applications will be for liquid rocket motor engines where improved conductivity for existing high temperature structural alloys used for rocket nozzle liners will provide a relatively low risk enhancement of performance for parts made by AM Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) Improved efficiency of waste energy recovery systems for commercial power stations and geothermal energy to reduce nations reliance on fossil fuels
