Metal AM Using Vibrational Resonance In-Space via Cold-Welding
Keng Hsu
Abstract
Current metal additive manufacturing processes predominantly use heat energy to achieve shaping and joining. The energy use efficiency and workflow process physics of these technologies severely limit their applicability in the extreme environment of space. A new method is demonstrated in this work for metal 3D printing that does not rely on thermal melt-fusion of feedstock materials. In this method, continuous shaping and joining of solid metal fine wires to form 3D objects is demonstrated. Net shape components from hard-to-weld alloys Al6061 are formed using this new technique. Evaluation of process capability, printed material property, process energy consumption of this new technique is provided in the context of its applicability in In-Space 3D printing applications.