Tool Coatings as a Strategy to Eliminate Lubrication for In-Space Manufacturing of AA1100-O via Single Point Incremental Forming (SPIF)

With recent increases in space travel and exploration, the need for in-space manufacturing (ISM) has become extremely prevalent. Limitations, including cost and payload, make the traditional approach of transporting pre-fabricated components impractical. Single point incremental forming (SPIF) offers a promising solution. SPIF uses a hemispherical tool to locally deform a metal sheet into user-defined geometries. This process is unaffected by microgravity and vacuum environments but uses lubrication during forming, potentially causing outgassing. Three tungsten carbide tools are used with SPIF: uncoated, diamond-like carbon (DLC) coating, and titanium diboride (TiB2) coating, without lubrication. The tool coatings enabled successful forming processes, while the uncoated tool resulted in failed parts in the absence of lubrication. The tool coatings provided increased resistance to aluminum buildup during forming and improved surface finish in the formed parts. SPIF can revolutionize ISM by enabling rapid production of sheet metal components in microgravity and vacuum environments without lubrication.