This thesis examines the thermal distribution and material behavior in in-space additive manufacturing (ISAM) using metal directed energy deposition (DED), addressing challenges of the orbital environment, including microgravity and vacuum. Experimental studies with a Scandium-modified Al-5183 alloy, conducted via Wire Are Additive Manufacturing, validated heat transfer coefficients and simulated ISAM thermal profiles. A finite element model, developed in Ansys Mechanical and calibrated with experimental data, accurately predicted overall thermal histories despite underestimating melt pool temperatures. Applied to orbital conditions, the model showed environmental healing effects were minimal for small components but significant for larger structures, supporting ISAM’s potential for space infrastructure. Material analysis revealed enhanced mechanical properties due to Scandium addition, with refined grains and Al3Sc precipitates. Integrating experiments, simulations, and characterization, this work advances ISAM thermal modeling, offering insights for future refinements in simulation accuracy and orbital testing.

It has been over 50 years since man first set foot on the Moon and proved that mankind could extend its borders beyond Earth, and yet no permanent lunar outpost has been set yet. Similar to how the construction of larger ports allowed for the exploration of the New World in the Renaissance, human exploration of space requires infrastructure beyond that required for spaceships and launchers. As our only natural satellite, the Moon is the best choice for a permanent base, one that would be capable of refuelling interplanetary missions, providing plentiful resources for the needs of people on Earth, and giving opportunities for fundamental research...