Two-Dimensional Laser Melting of Lunar Regolith Simulant Using the MOONRISE Payload on a Mobile Manipulator.

Laser melting experiments were carried out with the MOONRISE payload, installed on the mobile manipulator, MIRA3D. The MOONRISE payload was developed to demonstrate the feasibility of additive processing of lunar regolith with the help of lasers on the Moon within a lunar surface mission in the next years. The development of hardware for the flight to the moon is well advanced and, if successful, would pave the way for the use of laser melting for production of components from regolith. The aim of the experiments described in this article was to test the planned scenario on the Moon, especially the interaction between laser payload, manipulator, and soil surface, and to identify suitable process parameters for production of two-dimensional (2D) objects. The ability to produce 2D objects is an important intermediate step on the way to produce large three-dimensional structures such as habitats, walls, or foundations. During the experiments, specimens with a size of ∼20 × 20 × 4 mm were repeatedly produced. As analog material, two synthetic lunar soils produced with the modular regolith simulant systems from Technische Universität Braunschweig (TUBS) were used. The experiments were conducted under Earth gravity and atmospheric conditions. This article describes the hardware used, procedure for carrying out the experiments, and properties of the produced samples.

Development of a Laser Powder Bed Fusion Process Tailored for the Additive Manufacturing of High-Quality Components Made of the Commercial Magnesium Alloy WE43.

Additive manufacturing (AM) has become increasingly important over the last decade and the quality of the products generated with AM technology has strongly improved. The most common metals that are processed by AM techniques are steel, titanium (Ti) or aluminum (Al) alloys. However, the proportion of magnesium (Mg) in AM is still negligible, possibly due to the poor processability of Mg in comparison to other metals. Mg parts are usually produced by various casting processes and the experiences in additive manufacturing of Mg are still limited. To address this issue, a parameter screening was conducted in the present study with experiments designed to find the most influential process parameters. In a second step, these parameters were optimized in order to fabricate parts with the highest relative density. This experiment led to processing parameters with which specimens with relative densities above 99.9% could be created. These high-density specimens were then utilized in the fabrication of test pieces with several different geometries, in order to compare the material properties resulting from both the casting process and the powder bed fusion (PBF-LB) process. In this comparison, the compositions of the occurring phases and the alloys' microstructures as well as the mechanical properties were investigated. Typically, the microstructure of metal parts, produced by PBF-LB, consisted of much finer grains compared to as-cast parts. Consequently, the strength of Mg parts generated by PBF-LB could be further increased.