Exploring Metal Additive Manufacturing in Martian Atmospheric Environments

Author

Zane Mebruer, University of Arkansas, FayettevilleFollow

Date of Graduation

5-2025

Document Type

Thesis

Degree Name

Bachelor of Science in Mechanical Engineering

Degree Level

Undergraduate

Department

Mechanical Engineering

Advisor/Mentor

Shou, Wan

Committee Member

Wejinya, Uche

Abstract

On-surface manufacturing is key to the success of a planetary colonization, especially that of Mars. However, traditional subtractive manufacturing processes are equipment, energy, and material intensive, meaning novel additive manufacturing (AM) processes must be pursued for this end. Selective laser melting, one of the most effective and versatile AM methods, would be incredibly beneficial to a Martian mission but requires an artificial argon atmosphere to create effective parts. The purpose of this study was to examine if carbon dioxide, the gas that makes up over 95% of Mars’ surface atmosphere, would be a sufficient substitute for argon in SLM fabrication. One- and two-dimensional SLM parts were created out of 316L steel in argon, CO2 and ambient atmospheres at a variety of laser parameters to examine the effects of atmospheric composition on ideal parameters, part surface quality, part cohesion, and oxidation effects. It was found that atmosphere had little to no effect on parameter choice and that no specific parameter had a controlling effect on part quality, but instead a balance of parameters was required to maintain thermal effects in an equilibrium range. CO2 was determined to be slightly inferior to argon in terms of surface quality, cohesion, and oxidation levels of manufactured parts, but was superior to ambient atmosphere. Additionally, carbon nanotubes at 1 wt% were incorporated into the 316L steel to test resulting effects on the tested material properties. Little to no difference in surface quality or part cohesion was examined, but oxidation levels were lowered which may lead to other superior material properties as a result of their inclusion.

Keywords

Additive Manufacturing; Selective Laser Melting; 316L Steel; Carbon Dioxide; Carbon Nanotubes

Citation

Mebruer, Z. (2025). Exploring Metal Additive Manufacturing in Martian Atmospheric Environments. Mechanical Engineering Undergraduate Honors Theses Retrieved from https://scholarworks.uark.edu/meeguht/137