Numerical simulation approach for Laser Melting of lunar regolith using an enthalpy-based model

Abstract

The Moon is considered a future destination for international space exploration. Transport costs to the Moon are enormous, requiring the use of available resources to build infrastructure. Lunar regolith, predominantly found in the form of dust, covers the entire Moon’s terrain. A promising approach to process regolith is laser-based additive manufacturing, which aims to melt it directly on the surface. This paper presents a finite element simulation model to investigate the effects of laser power and feed rate variation on the melting process, with the objective to predict experimentally unexplored parameter ranges. The focus of this study is the phase transition from solid to liquid, implemented by an enthalpy model. Validation is carried out using experimental melting tests with regolith simulants. Despite limited experimental data, the observed effects are consistent with the simulation results, confirming that sample thickness increases with laser power and decreases with feed rate.