Comparison study of ductile iron produced with Martian regolith harvested iron from ionic liquids and Bosch byproduct carbon for in-situ resource utilization versus commercially available 65-45-12 ductile iron

As researchers continue to study methods to facilitate long-term missions beyond low-Earth orbit, the ability to manufacture high-quality mechanical and structural components on the Lunar and Martian surfaces remains a crucial piece to the puzzle for a sustained presence. Due to the immense cost of sending supplies to extraterrestrial bodies, in-situ resource utilization (ISRU) methods are critical for the success and feasibility of these habitation missions. Ionic liquids (ILs) are currently being studied at NASA’s Marshall Space Flight Center (MSFC) to harvest elemental metals from meteorites and regolith minerals. Additionally, the Bosch process is being explored as a life support system at MSFC for oxygen (O₂) regeneration, rendering a byproduct of elemental carbon (C). In this investigation, the viability of casting ductile iron (DI) using IL-sourced iron (IL-Fe) and Bosch C was studied given the range of applications and performance of DI as an as-cast alloy. Ingots were produced using commercial elements to simulate the use of IL-Fe with C sourced from the byproduct C of the Bosch process. Samples were cast and compared to commercially available 65–45-12 DI with phase transformation diagrams, microstructures, and hardness. Results showed that IL-sourced elements are a viable source of elemental alloying materials for a range of DI alloys, with some limitations.