Mechanical behaviour of additively manufactured lunar regolith simulant components

Additive manufacturing and its related techniques have frequently been put forward as a promising candidate for planetary in-situ manufacturing, from building life-sustaining habitats on the Moon to fabricating various replacements parts, aiming to support future extra-terrestrial human activity. This paper investigates the mechanical behaviour of lunar regolith simulant material components, which is a potential future space engineering material, manufactured by a laser-based powder bed fusion additive manufacturing system. The influence of laser energy input during processing was associated with the evolution of component porosity, measured via optical and scanning electron microscopy in combination with gas expansion pycnometry. The compressive strength performance and Vickers micro-hardness of the components were analysed and related back to the processing history and resultant microstructure of the lunar regolith simulant build material. Fabricated structures exhibited a relative porosity of 44–49% and densities ranging from 1.76 to 2.3 g cm−3, with a maximum compressive strength of 4.2 ± 0.1 MPa and elastic modulus of 287.3 ± 6.6 MPa, the former is comparable to a typical masonry clay brick (3.5 MPa). The additive manufacturing parts also had an average hardness value of 657 ± 14 HV0.05/15, better than borosilicate glass (580 HV). This study has shed significant insight into realising the potential of a laser-based powder bed fusion additive manufacturing process to deliver functional engineering assets via in-situ and abundant material sources that can be potentially used for future engineering applications in aerospace and astronautics.

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Correlation between surface texture and internal defects in laser powder-bed fusion additive manufacturing

Scientific Reports ◽

10.1038/s41598-021-02240-z ◽

2021 ◽

Vol 11 (1) ◽

Author(s):

Makiko Yonehara ◽

Chika Kato ◽

Toshi-Taka Ikeshoji ◽

Koki Takeshita ◽

Hideki Kyogoku

Keyword(s):

Additive Manufacturing ◽

Surface Texture ◽

In Situ Monitoring ◽

Mean Square ◽

Powder Bed Fusion ◽

Internal Defects ◽

Powder Bed ◽

Texture Parameters ◽

Areal Surface

AbstractThe availability of an in-situ monitoring and feedback control system during the implementation of metal additive manufacturing technology ensures that high-quality finished parts are manufactured. This study aims to investigate the correlation between the surface texture and internal defects or density of laser-beam powder-bed fusion (LB-PBF) parts. In this study, 120 cubic specimens were fabricated via application of the LB-PBF process to the IN 718 Ni alloy powder. The density and 35 areal surface-texture parameters of manufactured specimens were determined based on the ISO 25,178–2 standard. Using a statistical method, a strong correlation was observed between the areal surface-texture parameters and density or internal defects within specimens. In particular, the areal surface-texture parameters of reduced dale height, core height, root-mean-square height, and root-mean-square gradient demonstrate a strong correlation with specimen density. Therefore, in-situ monitoring of these areal surface-texture parameters can facilitate their use as control variables in the feedback system.

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Evaluation of Electron Beam Powder Bed Fusion Additive Manufacturing of High Purity Copper for Overhang Structures Using In-Situ Real Time Backscatter Electron Monitoring

Procedia Manufacturing ◽

10.1016/j.promfg.2020.05.120 ◽

2020 ◽

Vol 48 ◽

pp. 828-838

Author(s):

Chris Ledford ◽

Chris Rock ◽

Mouda Tung ◽

Hongliang Wang ◽

James Schroth ◽

...

Keyword(s):

Electron Beam ◽

Additive Manufacturing ◽

Real Time ◽

High Purity ◽

Powder Bed Fusion ◽

Backscatter Electron ◽

Powder Bed ◽

Purity Copper

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In-situ characterization of laser-powder interaction and cooling rates through high-speed imaging of powder bed fusion additive manufacturing

Materials & Design ◽

10.1016/j.matdes.2017.09.044 ◽

2017 ◽

Vol 135 ◽

pp. 385-396 ◽

Cited By ~ 100

Author(s):

Umberto Scipioni Bertoli ◽

Gabe Guss ◽

Sheldon Wu ◽

Manyalibo J. Matthews ◽

Julie M. Schoenung

Keyword(s):

Additive Manufacturing ◽

High Speed ◽

Powder Bed Fusion ◽

In Situ Characterization ◽

High Speed Imaging ◽

Cooling Rates ◽

Powder Bed

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Digitally Twinned Additive Manufacturing: Detecting Flaws in Laser Powder Bed Fusion by Combining Thermal Simulations with In-situ Meltpool Sensor Data

Materials & Design ◽

10.1016/j.matdes.2021.110167 ◽

2021 ◽

pp. 110167

Author(s):

R. Yavari ◽

A. Riensche ◽

E. Tekerek ◽

L. Jacquemetton ◽

H. Halliday ◽

...

Keyword(s):

Additive Manufacturing ◽

Sensor Data ◽

Powder Bed Fusion ◽

Laser Powder Bed Fusion ◽

Powder Bed ◽

Thermal Simulations

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In-situ Synchrotron imaging of keyhole mode multi-layer laser powder bed fusion additive manufacturing

Applied Materials Today ◽

10.1016/j.apmt.2020.100650 ◽

2020 ◽

Vol 20 ◽

pp. 100650 ◽

Cited By ~ 1

Author(s):

Yunhui Chen ◽

Samuel J. Clark ◽

Chu Lun Alex Leung ◽

Lorna Sinclair ◽

Sebastian Marussi ◽

...

Keyword(s):

Additive Manufacturing ◽

Powder Bed Fusion ◽

Laser Powder Bed Fusion ◽

Powder Bed ◽

Synchrotron Imaging

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Ultrasonics for monitoring melt pool dynamics and in situ sensing of microstructure during powder bed fusion additive manufacturing

The Journal of the Acoustical Society of America ◽

10.1121/10.0008378 ◽

2021 ◽

Vol 150 (4) ◽

pp. A307-A307

Author(s):

Christopher M. Kube ◽

Nathan Kizer ◽

Abdalla Nassar ◽

Edward Reutzel ◽

Haifeng Zhang ◽

...

Keyword(s):

Additive Manufacturing ◽

Powder Bed Fusion ◽

Powder Bed ◽

Melt Pool ◽

In Situ Sensing

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Fundamental Requirements for Data Representations in Laser-Based Powder Bed Fusion

Volume 1: Processing ◽

10.1115/msec2015-9439 ◽

2015 ◽

Cited By ~ 1

Author(s):

Shaw C. Feng ◽

Paul W. Witherell ◽

Gaurav Ameta ◽

Duck Bong Kim

Keyword(s):

Additive Manufacturing ◽

Heterogeneous Systems ◽

Powder Bed Fusion ◽

Process Data ◽

Data Interoperability ◽

Powder Bed ◽

Related Data ◽

Data Representations ◽

Am Processes

Additive Manufacturing (AM) processes intertwine aspects of many different engineering-related disciplines, such as material metrology, design, in-situ and off-line measurements, and controls. Due to the increasing complexity of AM systems and processes, data cannot be shared among heterogeneous systems because of a lack of a common vocabulary and data interoperability methods. This paper aims to address insufficiencies in laser-based Powder Bed Fusion (PBF), a specific AM process, data representations to improve data management and reuse in PBF. Our approach is to formally decompose the processes and align PBF process-specifics with information elements as fundamental requirements for representing process-related data. The paper defines the organization and flow of process information. After modeling selected PBF processes and sub-processes as activities, we discuss requirements for the development of more advanced process data models that provide common terminology and process knowledge for managing data from various stages in AM.

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