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<p>Advanced manufacturing techniques have enabled thin-walled aluminum features to be manufactured for lightweight structural applications, such as wheels for planetary rovers. However, as the thickness of the structural elements decreases, the deviation from bulk material properties&#xa0;must be considered. In this work, we compare the processing limits and performance of thin-walled aluminum structures manufactured via laser powder bed fusion (LPBF) and conventional abrasive waterjet. Using Al6061‐RAM2 powder in LPBF, we characterized minimum achievable wall thickness and the effects of chemical etching on dimensional fidelity. Minimum wall thickness of 451&#xa0;µm (LPBF as-printed), 250&#xa0;µm (LPBF and etched), 319&#xa0;µm (waterjet Al 6061), and 270&#xa0;µm (waterjet Al 7075) were achieved. Dimensional accuracy degraded with decreasing wall thickness across all conditions, with percent error exceeding 10% for sub-millimeter walls. Tensile testing revealed yield strength and ultimate strength reductions exceeding 40‐50% in some cases relative to bulk values, attributed to the increasing ratio of surface roughness and defect scale to wall thickness. Post-process T6 heat treatment of LPBF Al6061‐RAM2 thin walls significantly recovered tensile strength, with heat-treated samples approaching the nominal bulk alloy ultimate tensile strength of 331&#xa0;MPa, highlighting the importance of post-processing for precipitation-hardening aluminum alloys processed via LPBF. Additionally, lightweight wheel architectures were fabricated via additive and conventional manufacturing as prototypes to assess structural integrity under loading conditions relevant to lunar and Mars surface operation. These findings inform the design and application of thin-wall aluminum components for lightweight mobility systems in extraterrestrial environments.</p>

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Fabrication Limits and Mechanical Performance of Thin-Walled Aluminum Structures Fabricated via Powder Bed Fusion and Abrasive Waterjet: Toward Lightweight, High-Performance Rover Wheels

  • 期刊论文

  • 发表日期：

    2026年5月7日

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  • Daniel Oropeza,
  • Anthony Botros,
  • Eddie Barajas,
  • Alec Perkins,
  • Samad Firdosy,
  • Douglas C. Hofmann

摘要

Advanced manufacturing techniques have enabled thin-walled aluminum features to be manufactured for lightweight structural applications, such as wheels for planetary rovers. However, as the thickness of the structural elements decreases, the deviation from bulk material properties must be considered. In this work, we compare the processing limits and performance of thin-walled aluminum structures manufactured via laser powder bed fusion (LPBF) and conventional abrasive waterjet. Using Al6061‐RAM2 powder in LPBF, we characterized minimum achievable wall thickness and the effects of chemical etching on dimensional fidelity. Minimum wall thickness of 451 µm (LPBF as-printed), 250 µm (LPBF and etched), 319 µm (waterjet Al 6061), and 270 µm (waterjet Al 7075) were achieved. Dimensional accuracy degraded with decreasing wall thickness across all conditions, with percent error exceeding 10% for sub-millimeter walls. Tensile testing revealed yield strength and ultimate strength reductions exceeding 40‐50% in some cases relative to bulk values, attributed to the increasing ratio of surface roughness and defect scale to wall thickness. Post-process T6 heat treatment of LPBF Al6061‐RAM2 thin walls significantly recovered tensile strength, with heat-treated samples approaching the nominal bulk alloy ultimate tensile strength of 331 MPa, highlighting the importance of post-processing for precipitation-hardening aluminum alloys processed via LPBF. Additionally, lightweight wheel architectures were fabricated via additive and conventional manufacturing as prototypes to assess structural integrity under loading conditions relevant to lunar and Mars surface operation. These findings inform the design and application of thin-wall aluminum components for lightweight mobility systems in extraterrestrial environments.