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“ Manufacturing Systems of the Mars Settlement ” Local Steel, Aluminum, and Glass. Damon Ellender Programming Team [email protected] Manufacturing. Local Manufacturing is key to long-term planetary settlement. Requirements. Steel Processing 400kg/day 1500K

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Manufacturing systems of the mars settlement local steel aluminum and glass

Manufacturing Systems of the Mars Settlement”Local Steel, Aluminum, and Glass

Damon Ellender

Programming Team

[email protected]


Manufacturing
Manufacturing

  • Local Manufacturing is key to long-term planetary settlement


Requirements
Requirements

  • Steel Processing 400kg/day 1500K

  • Aluminum Processing 25kg/day 1000K

  • Glass Processing 200kg/day 1200K-1400K

  • Manufactured Products as needed for construction(i.e. Structural, wire,…)

  • Dual use or Flexible equipment used where possible


Glass process
Glass Process

  • Floated on Tin, Pilkington Process, 2mx4m float tray, made from local brick, covered to protect from dust

  • Cooled using CO2 in Lehr, 2mx2m, made from local brick. Rollers imported.

  • Cut into 1m x 1mx5mm glass panels for transport and further cutting.

  • Located Outdoors


Lcc steel process
LCC Steel Process

  • Low Carbon Content (LCC) Steel is better for low temperature application

  • All products made of 6mm Sheet or cast directly

  • Provision for Rolling ‘Strip’ depending on size of Steel Batch

  • Located Outdoors


Strip caster
Strip Caster

  • 6mm thick x2m wide

  • Can be outdoors though dust may require enclosed(not pressurized) areas

  • Pickling could also be done in enclosed area to ensure recovery of acids/caustics.


Typical strip casting process
Typical Strip Casting Process

  • All products made of 6mm Sheet or cast directly

  • Provision for Rolling ‘Strip’ depending on size of Steel Batch



Slab caster
Slab Caster

  • For Context

  • Not practical for amount of steel manufactured unless larger sections needed(i.e. rails)

  • Batch Casting or Direct Chill better alternative


Aluminum process
Aluminum Process

  • Strip Casting possible using same process as Steel

  • Direct Chill is also possible for Aluminum, not sure for Steel.


Aluminum direct chill casting
Aluminum Direct Chill Casting

  • Ingots Poured Vertically

  • Continuous Quench with Water or CO2

  • Once Mold is full, valve shuts, and ingot is rotated and pressed out by ram.

  • Other material could use this process(i.e steel)


Annealing furnace
Annealing Furnace

  • Located Outdoors

  • Capable of 1000K Temperatures

  • Capable of Controlled Cooling(using CO2)

  • Approximately 5mx1mx1m made from local Refractory

  • Heat Exchanger Imported(1m3, 100kg)

  • Uses Steam from Nuclear Reactor for Controlled Heating


Material transport
Material Transport

  • Need Glass, Steel, and Al transported from Refining to Manufacturing Airlock

  • Need Steel Rolls transported to Annealing Oven

  • Need Finished Products transported from Manufacturing Airlock to Area of Use

  • Rover or Automated Robot Carrier could easily be programmed to perform this function.


Products processing indoors
Products Processing (Indoors)

  • Sheet Metal

    • Foil Foil Mill (8m2,1000kg)

    • Ducting 4m brake(4m2, 200kg), Resistance Welder(.25m2,50kg), Rivets

    • Piping/Tubing Tube Mill(4m2,500kg)

    • Wire/Cable Stripper(4m2,200kg), Wire Mill(6m2, 500kg)

    • Mesh Expander(3m2,200kg)

    • Stamped

      • Housings Press and Dies(4m2, 200kg), Castings(.5m2, 50kg)

      • Structural Members Press and Dies(4m2,200kg), Castings(4m2,100kg)

      • Rover Wheels Castings(.5m2,50kg), Press and Dies(4m2, 200kg)

    • Roll Winder/Unwinder (4m2, 400kg)

  • Cast Metal

    • Structural Beams Direct Chilled, Castings(4m2, 100kg)

    • Castings Castings(1m2, 100kg)

      • Valves

      • Sprinklers

      • Rover Parts

  • Glass Glass Cutter(2mx1m, 100kg)

  • Coatings

    • Zinc Galvanizing Use Locally Made PE Tank, and Zinc

    • Powder Coating Line Includes Oven, 3mx3m, 400kg

    • Electroplating Use Locally Made PE Tank, and appropriate Eplating solution

  • Shop

    • One Off Manufacture Drill Press, CNC Lathe, CNC Milling Machine (H&V), Grinders, Cutters

    • Prototyping Rapid Prototyping System, Wax or Plastic Investments Minimum

  • Robots/Automation

    • 6 DOF Motoman Handles Resistance Welder, Plasma Cutter, and Manipulator

    • Crane Loading and Unloading of Heavy Items



Slitter
Slitter

  • May be used for making wire ribbon as well.


Cutting device
Cutting device

  • Diamond Saw

  • Cuts both steel and glass


Tubing mill formers
Tubing Mill-Formers

  • Rolls strips into a tube and welds.

  • Tubing out can be rolled or cut in lengths.


Coiler decoiler
Coiler/DeCoiler

  • Roll and Unrolls Tubing, Strip, Wire, and Cable.

  • 200kgs per unit

  • ~1mx2m floorspace


Steel mill control room
Steel Mill Control Room

  • For Context

  • Supervision of Process

    • Video

    • Instruments

    • Visual

  • Programming of new process


Powder coat oven
Powder Coat Oven

  • Finished Products

  • Durable Epoxy Coating

  • Can be used on Steel and Aluminum


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