Regolith-Rich PEEK Composite Bricks: Steps Towards Space-Ready Lunar Construction Materials

Abstract

This study introduces a novel composite construction material composed of lunar regolith combined with PEEK in dry powder form. The work demonstrates significant advantages over alternative methods, primarily by reducing production power consumption and simplifying the manufacturing process. Building on previous research that explored binder optimization through process simplification and targeting predefined shapes, this work delves deeper into a comparative analysis of high-performance thermoplastics. Among the various options, PEEK demonstrates the most favorable properties. The study investigates key processing parameters and evaluates the effects of vacuum processing and temperature testing on mechanical properties. The research also evaluates the effects of vacuum processing and temperature testing to assess the material’s performance under lunar conditions. Comparative analysis is performed with standard performance of various reinforced and unreinforced concretes and with standard requirements for construction bricks as per ASTM standards. This shows that the composite, with an organic binder content as low as 5 wt%, has great potential. Notably, the improvements achieved through vacuum curing ensure compliance with lunar environmental conditions and alignment with most Earth-based engineering standards. Samples compacted at 7.50 MPa with 10 wt% binder, and tested at room temperature, achieve a compression strength of 16.3 MPa, exceeding that of industrial floor bricks and matching that of building bricks used on Earth. Bending strength (7.4 MPa) aligns with steel fiber-reinforced and high-strength concretes. Vacuum curing further enhances these properties, with an observed increase of +66% in bending strength and +33% in compression strength.