ESA project: Skyrora tests Metalysis alloy “Tanbium” for 3D-printed engine components

Skyrora has commissioned Metalysis to supply a high-temperature-resistant powder for additively manufactured rocket nozzle components. The Refractory Complex Concentrated Alloy (RCCA) named Tanbium—computationally designed by Thermo-Calc Solutions—is set to undergo an initial nine-month qualification phase under a European Space Agency-funded program. The aim is to derisk material production and laser powder bed fusion (LPBF), demonstrate components such as combustion chambers and nozzles on Skyrora’s Skyprint 2 system, and gradually raise the Technology Readiness Level; later stages target TRL 6 in relevant environments.

Conventionally, alloys such as niobium-hafnium C103 or Inconel 718 are used in upper stages and engine components. Tanbium, a tantalum- and niobium-based composition, was designed using Integrated Computational Materials Engineering for higher hot-strength, improved ductility and oxidation resistance, and good laser processability. The partners expect longer burn times and increased reusability at potentially lower weight, without compromising required performance. Forecasts for European demand anticipate around 20 tonnes of alloy powder for space applications over the next five years.

Nitesh Shah, CEO Metalysis, commented: “Metalysis is very excited to be participating in this ESA funded project – utilising our alloy and high entropy alloy experience to produce the new alloy Tanbium, which is predicted to significantly enhance space component lifetimes. Skyrora came to us as the advanced materials partner because only our solid-state process can produce such a vast range of novel alloys. We look forward to successfully completing stage 1 of this project and moving to stages 2 and 3, and so making a real impact within the space propulsion market”.

Derek Harris, Director of Business Development and Communications, Skyrora, said: “This project reinforces Skyrora’s commitment to sovereign launch capability and materials innovation. The UK and Europe are currently heavily dependent on the US for C103 alloy, which is used across aerospace propulsion. Tanbium will enable full domestic sourcing with the powder produced by Metalysis, and components printed and tested by Skyrora, which will be simulated by Thermo-Calc to optimise material behaviour before physical testing. As a European launch vehicle manufacturer, not only will Tanbium align with our long-term vision for sustainable, high-performance space hardware, but it will also contribute to the ESA’s Net Zero Space ambitions.”

Metalysis produces Tanbium in the solid state via the FFC-Cambridge electrolysis process, bypassing the limitations of traditional melt metallurgy when alloying elements with large differences in properties. The powder format fits downstream consolidation routes such as LPBF.

Dr. Ida Berglund, Managing Director of Thermo-Calc Solutions, commented: “Scaling up refractory alloy powder production requires precision and quality. This project, and Metalysis experience and expertise in producing high quality refractory powders, help us bring Tanbium to the space propulsion market faster.”

Simon Hyde – European Space Agency (ESA) Technical Officer, said: “Ultra-High Temperature capable materials for rocket motor applications are a key item in the ESA work plans. This project addresses the challenge in an outstanding way: It combines bespoke alloy design with a unique production approach. These technologies are perfectly wedded to laser powder bed fusion, additive manufacturing. Using this, Tanbium alloy, the consortium are addressing a critical challenge for ultra-high temperature applications in Europe. They are opening a potentially rich seam for space applications and providing Europe with a resilient supply chain.”

For industry, the project represents a test bed for integrating computational materials design, solid-state production, and 3D printing into a robust chain for engine components.