An apparatus to study arc-wire direct energy metal deposition additive manufacturing process in a drop tower microgravity platform

Understanding the mechanisms and dynamics of molten metal droplet transfer within the plasma of a directed energy deposition arc process in microgravity is critical for optimizing the build process with minimal defects. This paper presents a unique experimental setup designed to investigate the transfer of molten metal droplets in the microgravity environment of a drop tower. The primary design of the apparatus revolves around accommodating, within the confines of the drop tower experimental capsule, essential components, including a high-speed camera with necessary filters for capturing molten metal droplets, a consumable electrode wire-arc setup, batteries, a linear traverse stage for single bead deposition, sensors, data acquisition systems, online communication systems, and the control system. These systems are secured to withstand the high deceleration forces at the end of a free fall in the drop tower. The arrangement has demonstrated consistent deposition outcomes, capturing clear images of droplet transfers using a high-speed camera along with voltage, current, and temperature data during the microgravity state induced by free fall. This apparatus will serve as a foundational element in establishing a viable additive manufacturing capability for space applications, as it provides fundamental insights into the transfer of molten metal droplets.