Dry Aerosol Deposition (DAD) is a ceramic coating process with the ability to build films and low profile 3D structures layer by layer and is therefore a promising additive manufacturing technique. DAD is unique because it uses kinetic energy rather than thermal energy for densification, and the result is a nearly theoretically dense, nano-crystalline ceramic. The main objectives of this work were to demonstrate the fabrication of adherent ceramic thick films onto a variety of substrates using lunar regolith simulant as feedstock, and to investigate the compositional relationships between feedstock and resultant films. Thick films were successfully deposited onto glass, steel and polyimide substrates via DAD. Using a sequential two-step deposition, films up to (but not limited to) 25 μm thickness were deposited onto steel. Surface roughness increased with thickness and with some influence from substrate material. Utilizing the DAD process, a very heterogeneous mixture of silicate and titanate mineral phases was transformed in a single step to a fully dense, nano-grained coating with spatially homogeneous composition at the micro-scale. The final composition of the coatings was found to deviate slightly from the feedstock powder, becoming richer in ilmenite (FeTiO₃) and poorer in plagioclase (feldspar) content. This work demonstrates the potential of DAD for in-space manufacturing and lunar In Situ Resource Utilization.

干法气溶胶沉积（DAD）是一种陶瓷涂层工艺，能够逐层构建薄膜和低剖面3D结构，因此是一种很有前途的增材制造技术。DAD的独特之处在于，它使用动能而非热能进行致密化，其结果是在理论上接近致密的纳米晶体陶瓷。这项工作的主要目的是演示使用月牙白粉模拟物作为原料在各种基材上制备粘附性陶瓷厚膜，并研究原料与所得膜之间的组成关系。厚膜通过DAD成功沉积在玻璃，钢和聚酰亚胺基材上。使用连续的两步沉积，将最大厚度为（但不限于）25μm的薄膜沉积到钢上。表面粗糙度随厚度和基材材料的影响而增加。利用DAD工艺，硅酸盐和钛酸盐矿物相的一种非常不均匀的混合物可以在一个步骤中转变为具有微观上空间均匀组成的完全致密的纳米颗粒涂层。发现涂料的最终成分与原料粉末略有偏离，富含钛铁矿（FeTiO₃）斜长石（长石）含量较差。这项工作证明了DAD在太空制造和月球原位资源利用方面的潜力。