Metal powder Additive Manufacturing in simulated microgravity
Researchers at Leibniz University Hannover, Germany, have successfully tested a flexible method for metal powder Additive Manufacturing under microgravity conditions. The research aims to enable the production and repair of components in microgravity environments, such as during space missions or directly on the Moon or Mars.
In order to achieve the goal of inhabiting the Moon or Mars, production processes need to be developed that enable everyday necessities to be produced there with the resources available on site. Notwithstanding the immensely challenging aspects of manufacturing in space, AM presents promising potential. Until now, the efficient production and repair of metal components under microgravity conditions has been challenging due to the complex nature of handling powder.
In collaboration with partners from Otto von Guericke University Magdeburg, researchers at Leibniz University Hannover have succeeded in producing components under microgravity conditions by means of Laser-based Directed Energy Deposition (DED) with metal powder. In this process, a laser melts the metal powder, which is then used to coat a substrate and build the component layer by layer. This could offer significant advantages for space missions, as damaged components could be repaired and costly spare parts could be avoided.
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Using the Einstein Elevator, the interdisciplinary research group were able to simulate the complex condition of a space mission. The large-scale research device, located at the university’s Hannover Institute of Technology (HITec), enables simulation of various gravitational conditions, such as microgravitational conditions or the intensive forces of a rocket launch. To conduct the project, the experiment was set up in an enclosed gondola in which all components, including the powder delivery system and laser system, were adapted to the special microgravity conditions. The materials that were processed included titanium and nickel alloys, which are widely used in the aerospace industry.
As a next step, the researchers plan to collaborate with Laser Zentrum Hannover (LZH) to process lunar regolith. Success in processing this grey dust, which is prevalent on the moon, would be decisive for future production on the moon or even Mars.
The research was conducted within the scope of the project “Additive manufacturing in microgravity using laser metal deposition,” which was funded by the German Research Foundation (DFG; project no. 456663377).
