Session: 03-20-02: Space Manufacturing II

Paper Number: 163663

An Icme Framework to Investigate the Scope of Solid-State Additive Manufacturing in Space Manufacturing and Repair Applications 

The integration of solid-state additive manufacturing techniques, particularly the Additive Friction Stir Deposition (AFSD) process, presents significant opportunities for in-space manufacturing and repair applications. This study proposes an Integrated Computational Materials Engineering (ICME) framework to investigate the scope and potential of AFSD in the context of space exploration. The AFSD process, characterized by its ability to deposit materials without melting, offers advantages such as reduced thermal distortion, enhanced mechanical properties, and the capability to utilize a wide range of materials, including aluminum alloys and advanced composites. These attributes make AFSD particularly suitable for fabricating components in the challenging environment of space, where weight reduction and structural integrity are paramount. State-of-the-art research shows that the capability of AFSD for layering stronger metals at various length scales has not been investigated yet due to the complexity of the problem and lack of feasible experimentations. Consequently, the full potential of a promising technology is yet to be unlocked, where the limiting factors with materials or challenges in process control need to be addressed with a rigorous multiscale analysis. The proposed ICME framework encompasses a multi-scale modeling approach that integrates molecular dynamics (MD) and finite element (FE) analysis to simulate the complex interactions during the AFSD process. This coupling allows for a comprehensive understanding of the thermal and mechanical behaviors of materials as they undergo deposition and solidification. The framework facilitates the optimization of process parameters, such as deposition speed and tool rotation, to enhance the quality and performance of the manufactured components. Additionally, the framework supports the evaluation of material and mechanical properties of the feedstock material, which are critical in space applications. In-space manufacturing using AFSD can significantly reduce the logistical challenges associated with transporting materials from Earth. By enabling the on-demand production of components, this technology can support long-duration missions and facilitate the repair of spacecraft and habitats in orbit. Furthermore, the ability to produce custom parts tailored to specific mission requirements enhances the versatility of space operations. This paper discusses the implications of the ICME framework for advancing the state of knowledge in solid-state additive manufacturing, particularly in the context of space applications. ICME can bridge the length scale gap between atomic-scale phenomena and macroscopic properties via carefully linking the kinematics of FE domains to that of MD, creating multi-scale models that offer more accurate and comprehensive predictions; and thus, enhancing the understanding of material performance. By leveraging the unique capabilities of AFSD, this research aims to contribute to the development of sustainable and efficient manufacturing solutions for future space exploration missions. The findings underscore the potential of solid-state additive manufacturing as a transformative technology in the aerospace sector, paving the way for innovative approaches to in-space manufacturing and repair.

Presenting Author: M Shafiqur Rahman Louisiana Tech University

Presenting Author Biography: Dr. M Shafiqur Rahman is an Assistant Professor in the Department of Mechanical Engineering at Louisiana Tech University. His area of research covers additive manufacturing/3D printing, solid mechanics, computational fluid dynamics, heat transfer, and machine learning.

Authors:

M Shafiqur Rahman Louisiana Tech University