Additive Manufacturing of Novel Transition Metal Boride Material System Resistant to Wear and Corrosion for Lunar and Planetary Exploration, Year 1

Completed TRL 2 (started at 1, targeting 2)

Description

This effort leverages results from a FY20 CIF/IRAD that explored LPBD parameters development for molybdenum aluminum boride, but the sample sizes were very small due to a limited amount of MAB powder provided by UND (~5 grams). Recent breakthroughs in processing of pure MAB-phase powders have unlocked a variety of powder processing methods, specifically additive manufacturing, that can potentially yield complex-shaped components.
Evaluation of laser powder bed deposition (LPBD) process parameters, coupled with production of MAB test articles using LPBD leveraging the promising results from the FY20 CIF/IRAD Tier 1 effort in which LPBD was applied to MAB for the first time, are the expected products of this effort. The progress will be assessed by fabricating test articles that will be characterized and compared to state-of-the-art ceramic material properties to determine how successful deposition of MAB powders using LPBD is at meeting or exceeding the hardness, density and dust adhesion properties for targeted space vehicle components. These results will help forge a path for processing other similarly promising MAB materials into components for application in missions to the Moon, Mars and beyond.

Benefits

Dust poses a significant threat to long-term durability of vehicles operating on Lunar and Martian surfaces. Abrasion, erosion and jamming of mechanisms with mating surfaces, such as gears, hinges and other mechanical joints were documented as a result of regolith dust incursion in the Apollo spacesuits. Furthermore, corrosion has been recently identified as an additional threat to materials durability and performance of Martian rovers due to the presence of water and brine. Advanced materials resistant to abrasive particles and corrosive environments are critically needed to enable human and robotic space exploration of the Moon and ultimately Mars, specifically safe human travel beyond low earth orbit. A recently developed novel ceramic material system, referred to as metal aluminum boride (MAB), possesses a unique structure that offers exceptional material properties well suited for demanding space applications; however, application of MAB phase materials has been restricted by limited fabrication routes yielding simple geometries.

Details

Technology area	Materials, Structures, Mechanical Systems, and Manufacturing > Materials
Program	Center Innovation Fund: LaRC CIF (LaRC CIF)
Lead organization	Langley Research Center, Hampton, VA
Start date	2020-10-01
End date	2021-09-30

Project contacts

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Valerie L Wiesner — valerie.l.wiesner@nasa.gov

How to get involved

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