In-Space Recycling System Using Electromagnetic Levitation and Induction to Process Metal into Rods

The proposed In-Space Recycling System builds upon the proven terrestrial application of electromagnetic levitation furnace technologies and the ISS Materials Science Laboratory - Electromagnetic Levitator heritage with the intent to reduce contact (with some aspects fully contactless) in metal recycling and reuse. Per the noted NASA TX12.4.6 Repurpose Processes gap and need for on-orbit servicing, assembly, and manufacturing (OSAM) our approach transforms spent components and larger structures into repurposed, useful products for on-orbit additive manufacturing, construction, and refueling.We propose the use of multiple, software-controlled electromagnetic induction coils for the generation of gradients and minimums for 3 axis positioning control, movement through the heating elements, and into a desired shape. An array of sensors will determine accuracy of shape and position, enabling contactless heating and transport of the metal sample through the entire process.Eight critical steps define the technical workflow:Delivery of cold heterogeneous material by 3rd parties (space tugs, cutting spent stages not simulated in this proposal).Introduction of heterogeneous material to foundry.Heating, meltingnbsp;Control of molten material in 3 axis spaceRefining and alloying of varied metal types and materials (post Phase I).mixing of material to a homogenous state.Movement from levitation furnace to adjacent chamber(s) (post Phase 1).Manipulation of molten metal and cooling into ingot or rod (post Phase 1).The input simulants will represent the varied dimensions and mass of rough-cut raw materials from spent upper stage or structure-scale space debris. The output will be a uniform metal rod or ingot as feedstock for use in multiple potential applications such as construction, additive manufacturing, and as a propellant for spacecraft. nbsp;