Friction Stir Extrusion (FSE) of Modular Lunar Solar Array Structures and Sub-Components

Lunar infrastructure development presents significant logistical challenges due to payload constraints and reliance on Earth-based manufacturing. This proposal introduces Friction Stir Extrusion (FSE) as an innovative solid-state manufacturing method to enable in situ production of modular structural components and electrical wiring for lunar solar tower arrays and other infrastructure. FSE utilizes a compact, low-power, gravity-insensitive extrusion process that transforms feedstock into high-quality, continuous extrusions of complex geometries without melting the material. Unlike traditional extrusion methods, this approach reduces energy consumption, enhances material properties, and is scalable to produce extrusions of virtually unlimited length. The Phase I effort will focus on designing and fabricating a single-pin FSE system with a ram-rod-style feed mechanism to validate key processing parameters. This will include extruding multiple geometries, performing metallographic and mechanical testing, and delivering samples to NASA for evaluation. Additionally, the study will assess surface finish enhancements via low-friction coatings and establish a roadmap for Phase II, which will expand the process to multi-pin extrusions and continuous feed systems for large-scale lunar applications. Beyond lunar construction, this technology has broad applications in terrestrial aerospace, defense, and industrial manufacturing, offering an energy-efficient alternative to traditional extrusion. The requested funding will demonstrate process feasibility, optimize extrusion parameters, and establish the groundwork for scalable lunar manufacturing, aligning with NASA's TX12.2 H5.01 objectives for modular lunar structures.