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Design and testing of selective laser melted structural component in AlSi9Cu3 alloy for a space dust analyser

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Abstract Space is one of the most avant-garde sectors for additive manufacturing as the inherent characteristics of this technology allow the creation of complex and lightweight 3D structures. Using this… Click to show full abstract

Abstract Space is one of the most avant-garde sectors for additive manufacturing as the inherent characteristics of this technology allow the creation of complex and lightweight 3D structures. Using this brand-new design tool, it was possible to design the pumping system holder of the MicroMED instrument, a particle analyser developed for ExoMars 2022 mission. The geometry of the holder was optimized using a finite element approach. The effectiveness of the proposed solution was evaluated by comparing the performance of two different designs using the AlSi9Cu3 alloy. One solution was based on micro-milling and the other on Selective Laser Melting. In order to validate the designed SLMed holder, a mockup was produced and successfully tested in the mission's mechanical environment.

Keywords: space; selective laser; analyser; design; alsi9cu3 alloy

Journal Title: Acta Astronautica
Year Published: 2021

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