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<p>This study presents a novel approach to upcycling metallic space debris into functional components. This is the first work to investigate the feasibility of using additive friction stir deposition (AFSD), a solid-state additive manufacturing (SSAM) technique, for in-space upcycling of space debris made into feedstock using continuous casting. In upcycling applications, AFSD combines the advantages of additive manufacturing of hard-to-weld metals and post-processing to produce near-net shape components. Simulated space debris, composed of AA6061, was fabricated into rods using continuous casting to create feedstock for twin rod AFSD (TR-AFSD). The resulting TR-AFSD deposit showed a reduction of many of the casting defects inherent in the feedstock material and exhibited a microstructure corresponding to improved material properties. These findings highlight the potential of AFSD for upcycling space debris through microstructure refinement and homogenization, enabling in-situ fabrication of high-performance components for sustainable space exploration.</p>

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Sustainable in-space manufacturing by upcycling metal space debris via a vertically integrated processing paradigm

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年7月2日

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  • Charlye R. Baker,
  • Ning Zhu,
  • Pruthul Kokkada Ravindranath,
  • Joseph W. Pawelski,
  • Cole L. Ritter,
  • Rachel M. Swinney,
  • Walter “Sparky” Matthews,
  • Trevor J. Fleck,
  • J. Brian Jordon,
  • Paul G. Allison

摘要

This study presents a novel approach to upcycling metallic space debris into functional components. This is the first work to investigate the feasibility of using additive friction stir deposition (AFSD), a solid-state additive manufacturing (SSAM) technique, for in-space upcycling of space debris made into feedstock using continuous casting. In upcycling applications, AFSD combines the advantages of additive manufacturing of hard-to-weld metals and post-processing to produce near-net shape components. Simulated space debris, composed of AA6061, was fabricated into rods using continuous casting to create feedstock for twin rod AFSD (TR-AFSD). The resulting TR-AFSD deposit showed a reduction of many of the casting defects inherent in the feedstock material and exhibited a microstructure corresponding to improved material properties. These findings highlight the potential of AFSD for upcycling space debris through microstructure refinement and homogenization, enabling in-situ fabrication of high-performance components for sustainable space exploration.