Laser-based Additive Manufacturing of Metal Parts from Powder in Microgravity
Final Report Abstract
The investigation of additive manufacturing technologies under the extreme conditions of outer space forms an essential basis for the implementation of future space missions. In this context, the Laser Powder Directed Energy Deposition (LP-DED) process in microgravity (µg) is being investigated for the first time as part of this research project. The process enables the additive manufacturing of complex components as well as the coating, joining, modification, functionalization and, above all, repair of existing components with high precision. As a result, material transportation and the supply of spare parts from Earth can be significantly reduced during space missions. Compared to the easier-to-handle, wire-based DED process, the powderbased process, especially in the context of In-Space Manufacturing (ISM), has the significant advantage that materials available on the Moon, Mars and asteroids can be used in-situ. In order to investigate the influence of gravity on the LP-DED process and the materials used, the specimens are manufactured both in the laboratory under 1 g and in the Einstein-Elevator in µg and then compared with each other. The Einstein-Elevator is an actively driven drop tower at the Leibniz University Hannover, which enables experiments under variable gravitational conditions from µg with a duration of 4 s up to hypergravity (up to 5 g). Two main objectives were achieved within the project: firstly, the development of a new gravity-independent powder conveyor and secondly, the development of an experimental setup for generating a stable and reproducible melting process using the LP-DED method in the Einstein-Elevator. Several powder conveyor concepts led to two prototypes, each capable of adjusting the powder mass flow independently of the carrier gas flow. The specimens manufactured utilized the alloys Ti-6Al-4V and Inconel 625, which are commonly used in the aerospace industry, whereby only the Ti-6Al-4V specimens could be evaluated during the project period. The research results indicate that the LP-DED process can be used not only on Earth, but also in space in µg. With regard to gravity, the results show no significant differences in geometry, microstructure and porosity. Further optimization of the experimental setup is necessary to make more precise statements regarding the influence of gravity. In conclusion, the present project makes a significant contribution to fundamental scientific research in the field of ISM.
Publications
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Laser Metal Deposition with Metal Powder in Microgravity. Deutscher Luft- und Raumfahrtkongress 2022, Dresden
Raupert, M.; Pusch, M.; Tahtali, E.; Sperling, R.; Heidt, A.; Lotz, C.; Katterfeld, A. & Overmeyer, L.
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Challenges in the development of the Laser Metal Deposition process for use in microgravity at the Einstein-Elevator. Lasers in Manufacturing Conference 2023
Raupert, M.; Tahtali, E.; Sperling, R.; Heidt, A.; Lotz, C. & Overmeyer, L.
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Development of a powder feeder for transporting metal powder in zero gravity. Logistics Journal: Proceedings, Nr. 20 (2024)
Pusch, M.; Hoffmann, N.; Raupert, M.; Lotz, C.; Overmeyer, L. & Katterfeld, A.
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Laser powder directed energy deposition and substrate-free single layer powder bed fusion under micro- and lunar gravity conditions. CIRP Annals, 74(1), 297-301.
Overmeyer, Ludger; Raupert, Marvin; Pusch, Matthias; Griemsmann, Tjorben; Katterfeld, André & Lotz, Christoph
