Selective laser sintering (SLS) of various lunar soil simulants for Moon base manufacturing: experimental results and numerical modelling

Danijela Ignjatovic Stupar; Grégoire Robert Chabrol; Abdoul Razak Ibrahim Baraze; Thierry Cutard; Sylvain Lecler; Jocelyne Brendle

doi:10.1117/12.2622108

20 May 2022 Selective laser sintering (SLS) of various lunar soil simulants for Moon base manufacturing: experimental results and numerical modelling

Danijela Ignjatovic Stupar, Grégoire Robert Chabrol, Abdoul Razak Ibrahim Baraze, Thierry Cutard, Sylvain Lecler, Jocelyne Brendle

Author Affiliations +

Proceedings Volume PC12135, 3D Printed Optics and Additive Photonic Manufacturing III; PC1213505 (2022) https://doi.org/10.1117/12.2622108
Event: SPIE Photonics Europe, 2022, Strasbourg, France

Abstract

Additive manufacturing using regolith, the main Lunar in-situ material resource, is offering a solution for long duration stay on the Moon or Mars. Using a homemade Selective Laser Sintering (SLS) machine with various lunar soil simulants, this study compares the experimental results with those of the simulations. Various lunar dust simulants were used and characterized by XRD. Specific care was taken when manipulating the nano-size powders. The experimental process was monitored by a pyrometer. The process conditions were optimized by numerical developed model on COMSOL Muliphysics. This model is based on data from the literature to cover material properties such as latent heat of fusion and temperature dependent parameters like the thermal conductivity, the thermal capacity, and the density. The meshing was adapted to the optimize the model efficiency. The laser source was modelled as a gaussian beam. The simulation was done with both a static and a moving beam where the effect of power, beam size and scanning speed was investigated. The evolution of temperature of the melt pool, the deformation of the structures and the evolution of the built-in stress were evaluated. This study shows that the outcome from the numerical model corroborates the experimental results in terms of spot size and temperature of the melt pool. The model predicts the failure of the sample for threshold values of power and scan speed for a given spot size.

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Danijela Ignjatovic Stupar, Grégoire Robert Chabrol, Abdoul Razak Ibrahim Baraze, Thierry Cutard, Sylvain Lecler, and Jocelyne Brendle "Selective laser sintering (SLS) of various lunar soil simulants for Moon base manufacturing: experimental results and numerical modelling", Proc. SPIE PC12135, 3D Printed Optics and Additive Photonic Manufacturing III, PC1213505 (20 May 2022); https://doi.org/10.1117/12.2622108

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KEYWORDS

Laser sintering

Manufacturing

Numerical modeling

Additive manufacturing

Data modeling

Mars

Space operations

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