Skip to main content
SpringerLink
Log in

Novel Selective Laser Printing Via Powder Bed Fusion of Ionic Liquid Harvested Iron for Martian Additive Manufacturing

  • Technical Article
  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

As the race to colonize Mars continues, the need for energy efficient, low waste manufacturing techniques remains as a major hurdle. Launching building materials from Earth is not feasible logistically or financially; therefore, in-situ resource utilization (ISRU) methods are required to ensure the success and longevity of these Martian colonies. Ionic liquids (ILs) are currently studied at NASA’s Marshall Space Flight Center (MSFC) as a means to harvest metallic elements from regolith oxides and meteorites. IL technology provides an energy efficient method to extracting critical manufacturing materials, such as iron (Fe), that can be used for structures, plumbing, and tools. In this study, IL-sourced Fe (IL-Fe) was used as feedstock for laser-based powder bed fusion (PBF-LB) to obtain a baseline of material characteristics for additive manufacturing. Samples were then investigated to determine microstructure, hardness, and chemical composition. IL-Fe showed potential as a feedstock for the production of metallic materials via laser-based additive manufacturing techniques.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1.
Fig. 2.
Fig. 3.
Fig. 4.
Fig. 5.
Fig. 6.
Fig. 7.
Fig. 8.
Fig. 9.
Fig. 10.

Similar content being viewed by others

References

  1. A. Yen, R. Gellert, B. Clark, D. Ming, P. King, M. Schmidt, L. Leshin, R. Morris, S. Squyres, and J. Campbell, “Evidence for a Global Martian Soil Composition Extends to Gale Crater,” (The Woodlands, TX), 2013, https://ntrs.nasa.gov/citations/20130009717.

  2. R. V. Morris, D. W. Ming, R. Gellert, D. T. Vaniman, D. L. Bish, D. F. Blake, S. J. Chipera, S. M. Morrison, R. T. Downs, E. B. Rampe, A. H. Treiman, A. S. Yen, C. N. Achilles, P. D. Archer, T. F. Bristow, P. Cavanaugh, K. Fenrdrich, J. A. Crisp, D. J. Des Marais, J. D. Farmer, J. P. Grotzinger, P. R. Mahaffy, A. C. McAdam, and J. M. Morookian, “Update on the Chemical Composition of Crystalline, Smectite, and Amorphous Components for Rocknest Soil and John Klein and Cumberland Mudstone Drill Fines at Gale Crater Mars,” (The Woodlands, TX), 2015, https://ntrs.nasa.gov/citations/20150001942.

  3. M. J. Rutherford, M. Minitti, and C. M. Weitz, “Compositions of Mars Rocks: SNC Meteorites, Differentiates, and Soils,” 1999, p 92–93, https://ntrs.nasa.gov/citations/20000012732.

  4. Gregory H. Peters, William Abbey, Gregory H. Bearman, Gregory S. Mungas, J. Anthony Smith, Robert C. Anderson, Susanne Douglas, and Luther W. Beegle, Mojave Mars Simulant—Characterization of a New Geologic Mars Analog, Icarus, 2008, 197(2), p 470–479.

  5. C.C. Allen, K.M. Jager, R.V. Morris, D.J. Lindstrom and J.P. Lockwood, Martian Soil Simulant Available for Scientific, Educational Study, EOS Trans. Am. Geophys. Union, 1998, 79(34), p 405–412.

    Article  Google Scholar 

  6. Carlton C. Allen, Richard V. Morris, David J. Lindstrom, Marilyn M. Lindstrom, and John P. Lockwood, “JSC Mars-1: Martian Soil Simulant,” 1997.

  7. L.J. Karr, P.A. Curreri, G.S. Thornton, K.E. Depew, J.M. Vankeuren, M. Regelman, E.T. Fox, M.J. Marone, D.N. Donovan, and M.S. Paley, “Ionic Liquid Facilitated Recovery of Metals and Oxygen from Regolith,” (Orlando, FL), 2018, https://ntrs.nasa.gov/citations/20180006392. Accessed 21 July 2021.

  8. J.A. Cherry, H.M. Davies, S. Mehmood, N.P. Lavery, S.G.R. Brown and J. Sienz, Investigation into the Effect of Process Parameters on Microstructural and Physical Properties of 316L Stainless Steel Parts by Selective Laser Melting, Int. J. Adv. Manuf. Technol., 2015, 76(5–8), p 869–879.

    Article  Google Scholar 

  9. A. Strondl, O. Lyckfeldt, H. Brodin and U. Ackelid, Characterization and Control of Powder Properties for Additive Manufacturing, JOM, 2015, 67(3), p 549–554.

    Article  CAS  Google Scholar 

  10. A. Rogalsky, I. Rishmawi, L. Brock and M. Vlasea, Low Cost Irregular Feed Stock for Laser Powder Bed Fusion, J. Manuf. Process., 2018, 35, p 446–456.

    Article  Google Scholar 

  11. Y. Bai, G. Wagner and C.B. Williams, Effect of Particle Size Distribution on Powder Packing and Sintering in Binder Jetting Additive Manufacturing of Metals, J. Manuf. Sci. Eng., 2017 https://doi.org/10.1115/1.4036640

    Article  Google Scholar 

  12. J.J. Restrepo and H.A. Colorado, Additive Manufacturing of Composites Made of Epoxy Resin with Magnetite Particles Fabricated with the Direct Ink Writing Technique, J. Compos. Mater., 2020, 54(5), p 647–657.

    Article  CAS  Google Scholar 

  13. R.-H. Fan, H.-L. Lü, K.-N. Sun, W.-X. Wang and X.-B. Yi, Kinetics of Thermite Reaction in Al-Fe2O3 System, Thermochim. Acta, 2006, 440(2), p 129–131.

    Article  CAS  Google Scholar 

  14. S. Dadbakhsh, L. Hao, P.G.E. Jerrard and D.Z. Zhang, Experimental Investigation on Selective Laser Melting Behaviour and Processing Windows of in Situ Reacted Al/Fe2O3 Powder Mixture, Powder Technol., 2012, 231, p 112–121.

    Article  CAS  Google Scholar 

  15. S. Dadbakhsh and L. Hao, Effect of Hot Isostatic Pressing (HIP) on Al Composite Parts Made from Laser Consolidated Al/Fe2O3 Powder Mixtures, J. Mater. Process. Technol., 2012, 212(11), p 2474–2483.

    Article  CAS  Google Scholar 

  16. D.E. Newbury and N.W.M. Ritchie, Performing Elemental Microanalysis with High Accuracy and High Precision by Scanning Electron Microscopy/Silicon Drift Detector Energy-Dispersive x-Ray Spectrometry (SEM/SDD-EDS), J. Mater. Sci., 2015, 50(2), p 493–518.

    Article  CAS  Google Scholar 

  17. I. Polozov, V. Sufiiarov, A. Kantyukov, N. Razumov, I. Goncharov, T. Makhmutov, A. Silin, A. Kim, K. Starikov, A. Shamshurin and A. Popovich, Microstructure, Densification, and Mechanical Properties of Titanium Intermetallic Alloy Manufactured by Laser Powder Bed Fusion Additive Manufacturing with High-Temperature Preheating Using Gas Atomized and Mechanically Alloyed Plasma Spheroidized Powders, Addit. Manuf., 2020, 34, p 101374.

    CAS  Google Scholar 

  18. N. Shen and K. Chou, “Numerical Thermal Analysis in Electron Beam Additive Manufacturing with Preheating Effects,” In: Proceedings of the 23rd solid freeform fabrication symposium, (Austin, TX), 2012, p 774–784.

  19. Wengai Yang, “The Structure and Properties of Mill Scale in Relation to Easy Removal,” (Sheffield, England), University of Sheffield, 2001, https://etheses.whiterose.ac.uk/15090/.

  20. Daryoush Ahmadi, “Oxide Scales Behavior During Descaling and Hot Rolling,” (Sheffield, England), University of Sheffield, 2019, https://etheses.whiterose.ac.uk/27100/.

  21. J. Shi and J. Ming, Influence of Mill Scale and Rust Layer on the Corrosion Resistance of Low-Alloy Steel in Simulated Concrete Pore Solution, Int. J. Miner. Metall. Mater., 2017, 24(1), p 64–74.

    Article  CAS  Google Scholar 

  22. E. Creutz and K. Downes, Magnetite Concrete for Radiation Shielding, J. Appl. Phys., 1949, 20(12), p 1236–1240.

    Article  CAS  Google Scholar 

  23. R.Y. Chen and W.Y.D. Yuen, A Study of the Scale Structure of Hot-Rolled Steel Strip by Simulated Coiling and Cooling, Oxid. Met., 2000, 53, p 539–560.

    Article  CAS  Google Scholar 

  24. R.Y. Chen and W.Y.D. Yuen, Oxide-Scale Structures Formed on Commercial Hot-Rolled Steel Strip and Their Formation Mechanisms, Oxid. Met., 2001, 56, p 89–118.

    Article  CAS  Google Scholar 

Download references

Acknowledgments

The authors would like to thank the staff of Marshall Space Flight’s EM22 department for providing the raw material used in this document. Additionally, we thank MSFC and the Center for Advanced Vehicular Systems for the funding of this project under Cont. No. 80NSSC20M0239 that made this research possible.

Funding

The authors would like to thank NASA’s Marshall Space Flight Center [NASA Cont.: 80NSSC20M0239] and the Center for Advanced Vehicular Systems for their funding which made this research possible.

Author information

Authors and Affiliations

  1. Center for Advanced Vehicular Systems, Mississippi State University, Mississippi State, MS, 39762, United States

    Blake C. Stewart, Haley R. Doude, Shiraz Mujahid & Hongjoo Rhee

  2. Department of Mechanical Engineering, Mississippi State University, Mississippi State, MS, 39762, United States

    Blake C. Stewart & Hongjoo Rhee

  3. Marshall Space Flight Center, National Aeronautics and Space Administration, Huntsville, AL, 35812, United States

    Eric T. Fox & Jennifer E. Edmunson

  4. Langely Research Center, National Aeronautics and Space Administration, Hampton, VA, 23666, United States

    Morgan B. Abney

Authors
  1. Blake C. Stewart
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Haley R. Doude
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Shiraz Mujahid
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Eric T. Fox
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jennifer E. Edmunson
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Morgan B. Abney
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Hongjoo Rhee
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hongjoo Rhee.

Ethics declarations

Conflict of interest

The authors declare that there is no conflict of interest regarding the publication of this paper.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

This invited article is part of a special issue in the Journal of Materials Engineering and Performance entitled “Space and Aerospace Exploration Revolution: Metal Additive Manufacturing.” The issue was organized by Shahrooz Nafisi, Relativity Space; Paul Gradl, NASA Marshall Space Flight Center; Douglas Hofmann, NASA Jet Propulsion Laboratory/California Institute of Technology; and Reza Ghomashchi, The University of Adelaide, Australia.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Stewart, B.C., Doude, H.R., Mujahid, S. et al. Novel Selective Laser Printing Via Powder Bed Fusion of Ionic Liquid Harvested Iron for Martian Additive Manufacturing. J. of Materi Eng and Perform 31, 6060–6068 (2022). https://doi.org/10.1007/s11665-022-06730-7

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-022-06730-7

Keywords

Search

Navigation