Testing a Novel Technology for a Key Material Property Measurement- Application to Advanced Manufacturing in Space

The Testing a Novel Technology for a Key Material Property Measurement-Application to Advanced Manufacturing in Space project will assess a novel method for manufacturing metals and alloys in microgravity. Specifically, this technique will evaluate electrostatic resonance conditions caused by oscillatory electric fields at two different levels of gravity. This resonance is correlated with interfacial tension and can be used as a method of measurement to predict the efficacy of printing metals and alloys in space. Data collected during parabolic flights will ultimately advance high-temperature interfacial printing systems.

Problem Statement 
An accurate knowledge of surface tension is required for effective additive manufacturing on a lunar base, especially for fabricating metals and alloys. Current state of the art for measuring surface tension is limited in scope and challenging in high-temperature environments. 

Technology Maturation 
Flight tests will evaluate the onset of resonance conditions by employing alternating electrostatic fields across the interface of two liquids and observing instabilities through imaging.The critical voltage difference to create the resonant state–which is strongly influenced by gravity level –is then correlated to the interfacial tension.Flight data will be compared with data from ground testing and predictions from current theoretical models, advancing the system to TRL 5 or 6.

Summary of Flight Test
2021-12-07 A technology using Faraday resonance with electrostatic forcing was successfully tested on the first flight campaign. This technology will be used to determine a key thermophysical property needed for efficient advanced manufacturing in space.
2022-05-16 A technology using Faraday resonance with electrostatic forcing was successfully tested on the first flight campaign. This technology will be used to determine a key thermophysical property needed for efficient advanced manufacturing in space.
2024-08-20 Two technogies using Faraday resonance with electrostatic forcing were successfully tested on the first reflight flight campaign.
The first technology used a liquid metal in contact with an encapsulant. This was the first time that such a system was tested in microgravity and the successful operation of the apparatus was proven. This technology will be used to determine a key thermophysical property needed for efficient advanced manufacturing in space.
The second technology is a novel means of electrostatic resonance in liquids for enhancing heat transfer in microgravity. This campaign was the first set of flights to test this technology.
 

Robust capabilities for additive manufacturing in microgravity are crucial for building a lunar base. This precise method for measuring surface tension would advance the ability to reliably print metals and alloys on the Moon. It could also be used for crystal growth and directed energy deposition, making the system versatile and highly innovative. This would benefit NASA missions and the commercial space industry.

Future Customers
•Producing metals and glasses for space-and ground-based applications
•Crystal growth
•In-space manufacturing

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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