Space Resources Roundtable VII (2005) 2012.pdf

PRODUCTION OF STEEL PRODUCTS IN SPACE USING ISRU IRON SOURCES AND CARBONYL METALLURGY. Bill Jenkin, Galactic Mining Industries, Inc., http://www.space-mining.com , 226 Elmdale Ave., Akron, OH 44313, 1-330-867-3628, [email protected]

Abstract: Steel production of critical compo- William C. Jenkin, age 92, with 17 U.S. Pat- nents using In Situ iron found in lunar, martian and ents, and has spent 45 years as a pioneer pursuing asteroidal materials is done using carbonyl metallurgi- technology and applications of the CARBONYL CVD cal techniques. Pressure vessel production will be fo- (chemical vapor deposition) PROCESS, proposed as a cused on in this presentation. Carbonyl metallurgical means to establish a metal fabrication technology on processes involve the gaseous digestion of iron content the moon. using carbon monoxide. The resultant iron penta- A pioneer who was never downsized or un- carbonyl is used in Chemical Vapor Deposition proc- employed, Bill began as a chemistry major at Oberlin esses to coat the interior or exterior of forms such as College (class of ’35), and became Chief Chemist in inflatables or other suitable mandrel surfaces. Such charge of a manufacturing quality control lab of 12 coatings build up to thicknesses necessary for use as technicians and chemists at Thompson Products, of pressure vessels, mirror contours, structural members Cleveland, Ohio. In 1946, Bill formed and sold Mid- and other important components for space bases and west Precision Casting to develop and successfully space stations. employ the precision investment process. Iron on the moon and mars will be reduced to the metallic state using hydrogen at elevated temps In 1958, he joined Commonwealth Engineer- (700 to 900C), while iron found on asteroids is already ing, an Ohio contract R&D firm, as Project Manager in the metallic state and does not require preprocessing of research primarily in nickel CVD. In 1968, Bill reduction. The iron must be in the metallic state in formed and managed the PYROLYTIC DIVISION of order for the carbonyl digestion process to take place. Akron Standard Mold, to develop nickel CVD into an Digestion of metallic iron takes place at temperatures industrial technology for use in low pressure molding near 75 to 100 degrees Celsius. The Chemical Vapor of plastics. By 1972, production technology was de- Deposition (CVD) of steel takes place at temperatures veloped in nickel shells weighing up to 100 lbs and as near 175 to 200 degrees Celsius. These low tempera- long as 6 feet were made. From 1972 to 1992, there ture processes allow space manufacturing of critical was continuous production of nickel shells, mostly components using In Situ Resources, thus multiplying molds, up to 200 pounds by successor organizations. the value of raw materials launched from earth. Raw Bill finally set up and operated his own laboratory to materials are hydrogen gas for the reduction of iron, continue contract research in nickel CVD until 1989, carbon monoxide for iron digestion, piping, pumps, when he contracted exclusively for INCO in a search heating apparatus, process control apparatus, inflat- for industrial applications. ables ( to provide shaped contours on which deposition The technology Bill Jenkin pioneered and de- takes place ), materials to produce mandrel or mold veloped led to formation of two manufacturing opera- surfaces, mining equipment capable of collecting soils tions in Wales, UK, and a contract with partners in and ores and grinding equipment. Magnetic separation Utah using his patented nanostrand technology. Bill may be used to concentrate iron content in raw ores is currently a partner with Galactic Mining Industries, and soils preparation. Gases such as hydrogen and Inc., to develop carbonyl manufacturing for mining carbon monoxide are recycled over and over again to and steel production on the moon, asteroids and on permit large quantities of steel products to be produced mars. with a limited initial supply of process gases and equipment. Galactic Mining Industries, Inc. is a Colorado Long term space programs will be able to ac- C-Corporation based in Denver, Colorado. The presi- complish much more by the use of In Situ Resources dent of Galactic Mining Industries, Inc. is Richard as feedstocks in the manufacture of critical compo- Westfall, [email protected] . Galactic Mining nents and equipment. Compared to the manufacture of Industries, Inc. was originally founded in 1989 and has steel on earth in high temperature foundries, these car- been pursuing the commercialization of space tech- bonyl processing techniques are low temperature tech- nologies useful in the colonization of space. niques. Limited quantities of equipment and process gases are able to process many times their weight in iron to produce many times their initial weight in steel products.