Session: 17-01-01: Research Posters

Paper Number: 149613

149613 - Exploring Metal Additive Manufacturing in Martian Atmospheric Environments 

Due to weight and space constraints in space flight, many items that will be needed in a manned Mars mission will need to be processed and/or manufactured on-planet. Additive manufacturing (AM), also known as 3-D printing, is widely considered as the most effective means of fabricating complex structures. Additive manufacturing, such as selective laser sintering or melting, can manufacture various components and parts in a relatively simple setup (motion stage and energy source), which can greatly reduce materials waste and simplify manufacturing procedures compared to traditional manufacturing methods. Among various additive manufacturing methods, Selective Laser Melting (SLM) is a notable option for potential in-space manufacturing of metals. The SLM process consists of a high-power laser that melts a bed of metal powder in a specified pattern. This process can be repeated layer by layer to produce a three-dimensional metallic part. Besides its relative efficiency and complex modeling capabilities in comparison to traditional manufacturing methods, SLM can also be easily adapted to a wide variety of metals, allowing for the versatility of construction that will be needed in a Mars colonization effort. However, while there is extensive data on SLM operation in an argon-based atmosphere (the industry standard), there is a knowledge gap surrounding SLM fabrication in Martian atmospheric conditions, which consists of mostly carbon dioxide (95%). The goal of this project is to examine the effects of a carbon dioxide atmosphere on SLM fabrication by constructing an artificial carbon dioxide atmospheric environment, fabricating various metallic samples within the simulated environment, and testing for differences in material strength and surface morphology compared to samples created in argon and atmospheric environments. Samples will be processed utilizing a high-power laser to melt a layer of metal particles deposited via spray. This process will be repeated several times with successive layers of metallic powder until a sufficient thickness is reached. This manufacturing process will be done in ambient, argon and carbon dioxide environments to test for outcomes on morphology. Atmospheric content levels will be consistently monitored and maintained throughout the fabrication process to ensure the reliability of the test. The quality of the produced samples will be determined using Scanning Electron Microscope (SEM) and Atomic Force Microscopy (AFM) scans. These scans will provide insight into the processing atmosphere’s effect on the surface morphology and surface roughness of the processed samples. The examined characteristic differences between atmospheric processing environments will provide a greater understanding of manufacturing within a Martian environment, an important step into man’s exploration of the solar system.

Presenting Author: Zane Mebruer University of Arkansas

Presenting Author Biography: Zane Mebruer is a class of 2025 Mechanical Engineering major at the University of Arkansas. Alongside his major in mechanical engineering, Zane is pursuing minors in the fields of physics and nanotechnology and a major concentration in aerospace technology. Zane has been actively involved in research under Dr. Wan Shou for 2 years, during which has done work on numerous projects in a wide variety of disciplines, including soft robotics, biodegradeable nanomaterials, and laser-based processing. His work has received numerous grants from sources including NASA and the University of Arkansas Honors College. After obtaining his bachelor's degree, Zane intends to further his education and research experience at a graduate institution in pursuit of a career in research and development.

Authors:

Zane Mebruer University of Arkansas
Wan Shou University of Arkansas