| Abstract Scope |
Aluminum alloys are ideal candidates for in-space manufacturing (ISM) due to their lightweight properties and low melting temperatures. A critical challenge in producing metallic components using fused deposition modeling (FDM) is ensuring the structural integrity of printed parts, which heavily relies on particle adhesion. To address this, we propose engineering the surface melt process to enhance particle cohesion and improve mechanical strength. Our study introduces a phase-field model of surface melting, utilizing experimentally derived surface energy parameters specific to Al 7075-T6 alloy feedstocks, measured via the sessile drop technique. We account for mechanical effects, including transformation and thermal strains, and compare the influence of elastic energy against cases lacking mechanical considerations. Two geometric configurations—cylindrical and spherical particles—are analyzed, revealing that cylindrical particles develop a more disordered microstructure upon size reduction compared to spherical particles. These insights provide a pathway for optimizing surface melting in ISM applications. |