3D Printed Magnetic-to-Non-magnetic Gradient Alloy Cold Encoder Shafts for Prediction and Control of Magnetic Permeability, Year 2

The objective is to solve the magnetization problems of MSL's Cold Encoder Shafts, which caused false index pulses and inaccurate measurements. Design and develop a gradient alloy cold encoder shaft fabricated by Additive Manufacturing (AM) using magnetic and non-magnetic alloys based on magnetic field sensitivity studies on MSL's Cold Encoders. A cold encoder shaft made of a gradient alloy with a non-magnetic region of the shaft in the area of the encoder would likely eliminate the issues of magnetic saturation. 3D print cold encoder shafts and witness coupons with Maraging 300 (or equivalent) and 316L stainless steel gradient alloys. Test witness coupons (tensile, fatigue, etc.) and 3D printed Cold Encoder Shaft in test bed.

Qualify new materials for motor control systems for future missions Mechanical and magnetic properties of additively manufactured gradient alloy structures would demonstrate low-cost solutions to magnetic saturation issues on MSL/Mars 2020. Demonstrate the capabilities of gradient alloys to create novel, complex components via AM. Savings with AM Utilizes less energy, material, and can cost less to fabricate hardware vs traditional subtractive manufacturing.

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