Material which could be used to build first colony on MARS
During crewed Mars missions in the coming years, finding ways to reduce supply loads and utilize local materials will be a crucial element to ensuring the success of our explorations of the Red Planet. To address this, researchers are working to achieve this goal, allowing Mars explorers to grow their own building materials directly on the Red Planet. Scientists are finding ways to turn Martian dirt into usable metals. This breakthrough could make it possible to build settlements on Mars without bringing everything from Earth. Swinburne and CSIRO researchers have successfully produced iron in Mars-like conditions, opening the door to metal production beyond Earth. The vision of establishing settlements on Mars has captured the imagination of billionaires, government space programs and space exploration advocates. However, building such colonies requires vast amounts of material, and transporting it all from Earth is not practical. To put it in perspective, sending NASA’s one-ton Perseverance Rover to Mars cost around US$243 million.
For CSIRO Postdoctoral Fellow and Swinburne graduate Dr Deddy Nababan, the solution may lie in Mars’s own soil, known as regolith. This new project, with support from NASA’s Innovative Advanced Concepts, the US space agency’s funding arm for radical, long-term concepts related to aerospace. The team spent years developing living substances which can form construction materials on their own, and they have now applied their work to autonomous construction on Mars, utilizing the local regolith. Swinburne and CSIRO researchers have successfully made iron under Mars-like conditions, opening to door to off-world metal production. “Sending metals to Mars from Earth might be feasible, but it’s not economical. Can you imagine bringing tonnes of metals to Mars? It’s just not practical,” Dr Nababan says. “Instead, we can use what’s available on Mars. It’s called in-situ resource utilization, or ISRU.” More specifically, Dr Nababan is looking at astrometallurgy, making metals in space.
This work may be the answer to bringing construction materials across vast distances and into challenging environments which are normally lacking in resources. Other attempts to forge construction materials from the Martian regolith have focused on addressing the material shortage, but remain impractical as they have overlooked the likely labour shortage which any early Mars missions will encounter. Creating solutions for these conditions called for bonding regolith particles with various compounds composed of magnesium or sulphur, as well as a geopolymer concept. Still, all of these required more intensive hands-on work than those early explorers would be able to dedicate to the project. There have been approaches attempting to minimize the required labour by relying on microbes to help power a self-growing technology. While bacteria and fungi can bind particles into more useful construction materials, such as bricks, the microbes involved often suffer from survivability issues. Previous attempts relied on a single species, requiring a great deal of care and nutrient feeding to remain viable, replacing the regolith bonding focus with an all new task: caring for the microbes.
As it turns out, Mars has all the ingredients needed to make native metals. This includes iron-rich oxides in regolith and carbon from its thin atmosphere, which acts as a reducing agent. Swinburne University of Technology astrometallurgist, Professor Akbar Rhamdhani, is working with Dr Nababan to test this process with regolith simulant, an artificial recreation of the stuff found of Mars. The researchers used a regolith simulant which mimics the materials found at Gale Crater on Mars. “We picked a simulant with very similar properties to that found at Gale Crater on Mars and processed them on Earth with simulated Mars conditions. This gives us a good idea of how the process would perform off-world,” he says. The simulant is placed inside a chamber at Mars surface pressure and heated at increasing temperatures. The experiments showed pure iron metal formation around 1000°C, with liquid silicon-iron alloys produced around 1400°C. “At high enough temperatures, all of the metals coalesced into one large droplet. This could then be separated from liquid slag the same way it is on Earth,” Professor Rhamdhani says. Along with Dr Nababan, Prof Rhamdhani is collaborating with CSIRO’s Dr Mark Pownceby to further advance the process. They’re particularly focused on making metals with zero waste, where the byproducts of the process are used to make useful items.
Minimizing astronauts’ commitments to construction-related labour was a major focus for the team. To that end, they produced a resilient multi-species synthetic community, resulting in a fully autonomous self-growing process which requires no external nutrients. The heterotrophic filamentous fungi that the team utilized have significantly greater survivability than heterotrophic bacteria, while promoting the formation of biominerals to serve as a bonding agent for regolith particles. Photoautotrophic diazotrophic cyanobacteria complete the synthetic lichen by converting atmospheric carbon dioxide and dinitrogen into oxygen and organic nutrients to feed the fungi and increase the carbonate ion concentration, which the fungi bind to their cell walls. The filamentous fungi complete the cycle by providing water, minerals and CO2 to the cyanobacteria. Both the fungi and cyanobacteria release biopolymers which adhere the regolith particles together.
In space exploration, in-situ resource utilization (ISRU) is becoming increasingly important because every kilogram launched aboard a rocket adds to the cost and complexity of a mission. Although launch costs are gradually decreasing, the scale of resources needed to support human exploration remains enormous. Significant progress is already being made, including the first off-world demonstration of ISRU. NASA’s MOXIE experiment, carried by the Mars Perseverance rover, successfully generated breathable oxygen from nothing more than the carbon dioxide in Mars’s atmosphere. Metal production is the next giant leap. Prof Rhamdhani hopes Mars-made alloys could be used as shells for housing or research facilities and in machinery for excavation. “There are certainly challenges. We need to better understand how these alloys would perform over time, and of course, whether this process can be recreated on the real Martian surface,” Prof Rhamdhani says. But in the meantime, Swinburne and its partners are doubling down. Prof Rhamdhani, together with Dr Nababan and Dr Matt Shaw, another CSIRO researcher and Swinburne alum, recently delivered a 4-day bespoke workshop on astrometallurgy in South Korea. The feedback was promising. “We’re starting to see increased interest in this field globally as the world gets serious about Mars exploration,” he says. “To make it happen, we’re going to need experts from many fields, mining, engineering, geology and much more.” For Dr Nababan, the benefits go beyond exploration. He hopes their research will also drive more efficient metallurgy here on Earth. “By doing this, I wish that I can help the development of space exploration, and at the end it will bring good to human life here on Earth.” In testing, the process was successful and fully autonomous, growing in a mixture of simulated regolith, inorganic liquid, light and air. With the material creation process demonstrated, the team is moving on to testing their regolith material.