Additively Manufactured Scalmalloy® EMU Spacesuit Bearings

Quadrus Advanced Manufacturing Division (QAMD) is pleased to present this proposal for the demonstration of the feasibility of an advanced bearing design solution that extends service life while significantly reducing weight. The current challenge with Titanium 6Al-4V (Ti6-4) bearings is galling and excessive wear due to the high loads applied to the bearing race and the stainless-steel balls. Our innovative approach involves replacing the bearing race and housing with nitrided Scalmalloy® which maintains wear performance while offering significant weight savings. QAMD has been certified by APWORKS to process Scalmalloy® since 2019. The nitriding process will ensure comparable surface hardness to the current Ti6-4 bearings which is crucial in limiting wear and galling. The primary technical objective is to demonstrate the feasibility of utilizing nitrided or TiC-reinforced Scalmalloy® for bearing races and housings in planetary spacesuit applications, achieving weight reduction while maintaining wear performance. Additionally, if necessary, an additively manufactured CoCr race insert will be evaluated as a high hardness contact surface while retaining Scalmalloy® for the housing to optimize mass efficiency. Quadrus Advanced Manufacturing Division aims to establish itself as a key supplier of advanced bearing solutions for next-generation spacesuits, particularly for NASA’s EMU and future planetary exploration suits. By demonstrating the feasibility of Scalmalloy®-based bearings with enhanced wear resistance and weight savings, we position ourselves as an integral partner to suit manufacturers such as Axiom Space, Collins Aerospace, and ILC Dover. Beyond the completion of Phase II, the goal is to transition from research and development to full-scale production, ensuring integration into NASA's lunar and Martian exploration programs, as well as commercial space ventures.