Investigating Selective Laser Sintering as a Manufacturing Method for Creating Mine Infrastructure in Off-Earth Mines

Transcription

1 Investigating Selective Laser Sintering as a Manufacturing Method for Creating Mine Infrastructure in Off-Earth Mines School of Mining Engineering Lachlan Colley BE (Mining) / BSc (Earth Science) Graduating semester 2, z

2 Objectives & Methodology Research the nature of space mining & the role of SLS technology. Construct a proof of concept ceramic SLS system.

3 Space Mining NASA Space Exploration Destination Systems Roadmap ISECG Global Exploration Roadmap Materials In situ resource utilisation Space based manufacturing: - Structures - Thermal Protection - Radiation Shielding - Propellants - Satellites - Spacecraft

4 Space Mines & Infrastructure Vertically Integrated design, mining, manufacturing, assembly & implementation Microgravity Flexible Designs Material efficiency Equipment automation & fully autonomous operation

5 Space Based Manufacturing November & December 2014 International Space Station Made In Space Incorporated in conjunction with NASA Fused Deposition Modeling Ratcheting socket wrench

6 Selective Laser Sintering Dr. Carl R. Deckard University of Texas at Austin Mid 1980 s DARPA 3x Patents from 1986 to 1990 Commercial Systems: - EOS - Trumpf - Paramount Industries

7 How It Works 1. Thin layer of powder is deposited 2. Laser scans shape 3. Second layer of powder is deposited 4. Laser scans second shape, shapes sinter together repeat.

8 Current Applications Moulds & Toolmaking EOS Biomedical EOS

9 Current Applications Turbocharger Manifolds Koenigsegg SuperDraco Rocket Motor SpaceX

10 Proof of Concept Ceramic SLS System Laser with CNC Control (X & Y Axes) Build Chamber with CNC Control (Z Axis) Powder (Feedstock)

11 Materials & Component Sourcing HX40A 40W CO 2 Laser Engraver Powder Build Chamber Laser Cutting & Table Construction 3D Printed Components CNC Control & Electronics Machining & Other Materials Powder Sourcing

12 SLS System Construction

13 Powder Sourcing No. Powder Name Source Location Abbreviation 1 Australian Lunar Simulant 1 Kulnura, Central Coast 2 Fly Ash Vales Point Power Station, Lake Macquarie 3 Cenospheres Vales Point Power Station, Lake Macquarie 4 Sandstone (in situ) Ravensworth Open-cut Coal, Hunter Valley 5 Siltstone (in situ) Ravensworth Open-cut Coal, Hunter Valley 6 Shale (in situ) Ravensworth Open-cut Coal, Hunter Valley ALS-1 / ALS Fly Ash Cenospheres Sandstone Siltstone Shale 7 Sydney Sand Unknown, Sydney Basin Sydney Sand

14 Powder Densities Approximate Bulk Densities (Following removal of >1.7mm particles) Density (g/cc) ALS FLY ASH CENOSPHERES SANDSTONE SILTSTONE SHALE SYDNEY SAND

15 Powder Grading 100 Cumulative Percent Retained (Following removal of >1.7mm particles) Percent Retained (By Weight) ALS FLY ASH CENOSPHERES SANDSTONE SILTSTONE SHALE SYDNEY SAND Sieve Size Retaining Powder (µm)

16 Size Distributions 0.5 Powder Size Distributions (0-500µm) Percent Retained (By Weight) ALS FLY ASH CENOSPHERES SANDSTONE SILTSTONE SHALE SYDNEY SAND Sieve Size Retaining Powder (µm)

17 Initial Testing ALS Fly Ash Sandstone Siltstone Shale Sydney Sand Cenospheres

18 Comparison to Lunar Regolith Apollo Lunar Regolith (Larry Taylor University of Tennessee) ALS

19 2D Test Shapes ALS Fly Ash Cenospheres Sandstone Siltstone Shale Sydney Sand

20 2D Test Shapes Sydney Sand

21 3D Shapes 1cm cube Fly Ash

22 Issues Clumping & streaking (moisture) Control system errors Hand Spreading

23 Conclusions Space based mining & mine infrastructure will be fundamentally different with high levels of automation & process integration. In situ resource utilisation (ISRU) will be key. Ceramic based SLS requires stringent quality control. The strength & density of final SLS ceramics were lower than would be practically required in space. ALS currently does not sinter well, most likely due to its Mafic composition. High silica content powders such as Fly Ash & Sand work more effectively. A space based SLS system is likely to work, however it will require further R&D. Cost effective ceramic SLS proof of concept (~ $3000 AUD). Practical & meaningful testing can be completed with very limited starting knowledge & a high level of determination.

24 Recommendations Fully automate the spreading process (reduce human error). Incorporate a heated bed (moisture control). Higher power laser (100W+) with more accurate optics. Look the ChemCam experiment aboard the MSL. From there Investigate sintered densities (Centrifugal assisted sintering). Investigate scan patterns further. Investigate the effects different powder sizes. Investigate brick shapes & geometries. Consider the SLS process for use in fabricating moulds for casting structural parts.

25 Questions? Selected References & Sources: Australian Centre for Space Engineering Research, An Australian Soil Simulant to Study Lunar Mining and Construction Leonhard Bernold, online video. Available from: < > Bonanno, A, Energy storage technology for use in manufacturing and power supply on the Moon, Honours thesis (published), The University of New South Wales, Sydney. EOS, New Initiative Combines Industrial 3D Printing with Free Medical-Implant Design Software [online]. Available from: < > [Accessed: 19 February 2015]. EOS, EOSINT M 280, Leading-edge system for the Additive Manufacturing of metal products directly from CAD data [online]. Available from: < > [Accessed: 14 May 2015]. ESA, Space Engineering and Technology, Building a Lunar Base with 3D Printing [online]. Available from: < > [Accessed 15 February 2015]. Foster, Foster + Partners works with European Space Agency to 3D print structures on the moon [online]. Available from: < > [Accessed: 20 March 2015]. Koenigsegg, One:1 Worlds first megacar [online]. Available from: < koenigsegg.com > [Accessed: 25 February 2015]. [Accessed: 10 March 2015]. Kruth, X. Wang, T. Laoui, L. Froyen, (2003) "Lasers and materials in selective laser sintering", Assembly Automation, Vol. 23 Issue: 4, pp Lewis, J S, Mining the Sky: Untold Riches from the Asteroid, Comets, and Planets [online]. Available from: < kiss.caltech.edu > [Accessed: 9 April 2015]. NASA, The Shuttle s Thermal Protection System (TPS) [online]. Available from: < history.nasa.gov > [Accessed: 1 May 2015]. NASA, DRAFT Human Exploration Destination Systems Roadmap, Technology Area 07 [online]. Available from: < > [Accessed: 15 January 2015]. NASA, SP-413 Space Settlements: A Design Study. Appendix E Mass Shielding [online]. Available from: < settlement.arc.nasa.gov > [Accessed: 3 February 2015]. NASA, Beyond Earth, Expanding human presence into the solar system [online]. Available from: < > [Accessed: 4 March 2015]. Planetary Resources, Prospecting and Exploration [online]. Available from: < > [Accessed: 7 May 2015]. Sonter, M J, The technical and economic feasibility of mining near-earth asteroids, PhD thesis (unpublished), University of Wollongong, Wollongong. Space X, Space X launces 3D-Printed part into space, creates printed engine chamber [online]. Available from: < > [Accessed: 5 February 2015]. Taylor, L, NASA s dirty secret: Moon Dust [online]. Available from: < esciencenews.com > [Accessed: 1 March 2015]. Yarlagadda, P K D V, Narayanan, S, GCMM 2004: 1st International Conference on Manufacturing and Management, pp (Narosa Publishing House, New Dehli).