Deutsches Zentrum für Luft- und Raumfahrt e.V.
Additive manufacturing (AM) technologies appear to be a tremendous opportunity to meet spaceflight requirements because they contribute to saving material, reducing mass to transport, and reducing production time. Laser-based powder bed fusion (LB-PBF) is one of the most versatile AM processes in terms of possible geometries and scalable process parameters, and is adaptable to a wide range of materials. Over the recent years this technology has matured and become a reliable alternative for manufacturing structural parts subjected to static high stresses, and for manufacturing parts with complex geometry or from materials difficult to process in traditional ways. It is the aim of this work to bring LB-PBF into space and manufacture parts from metal powders in a process independent of gravitational environment. A gas-flow-assisted powder stabilising system for microgravity was developed and tested on parabolic flights. Though the flights allowed to qualify the powder deposition and stability in microgravity, the weightlessness phases are too short (20 sec) to also allow for laser melting and therefore part manufacturing. As a transitional phase to building on-orbit, sounding rockets offer a good compromise between availability, cost, and microgravity time (6,5 min), and so a rocket payload (called MARS, Metal-based Additive manufacturing for Research in Space) capable of LB-PBF in microgravity was designed, constructed, qualified on parabolic flights, and flown several times on the DLR’s MAPHEUS sounding rocket. Powder of metallic glass AMZ4 was used as feedstock during the aforementioned sounding rocket campaigns. The 6,5 min available on MAPHEUS allows the building of around 8 layers of 100 µm thickness each. This serves as a proof of feasibility and is enough to carry out some structural investigations. Synchrotron measurements performed on the built samples indicate little differences between samples of AMZ4 produced in space and in lab.
Abstract
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