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Burnishing is an effective chipless finishing process for improving workpiece properties: hardness, vibration resistance and surface quality. The application of this technology is limited to rotationally symmetrical structures of deformable metals. Because of the multiaxial characteristics, the transfer of this force controlled technology on to prismatic shapes requires a comprehensive process development. The main purpose of this paper is the characterization of a plain burnishing process on aluminium EN AW 2007 with a linear moved, spherical diamond tool. The method of design of experiments was used to investigate the influence of different machined surfaces in conjunction with process parameters: burnishing force, burnishing direction, path distance and burnishing speed. FEM simulation was utilized for strain and stress analysis. The experiments show, that unlike the process parameters the initial surface roughness as 3rd order shape deviation does not have a significant influence on the finished surface. Furthermore a completely new surface is created by the process, with properties independent from the initial surface roughness.

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In recent years, space agencies like NASA and ESA have expanded their research activities in the field of Manufacturing in Space. These measures serve to reduce limitations and costs through fairing size, launch mass capabilities or logistic missions. The objective, in turn, is to develop technologies and processes that enable on-demand manufacturing for long-term space missions and on other celestial bodies. Within these research activities, in-situ resources utilization (ISRU) and recycling are major topics. Consequently, this paper considers what is required on-demand in future space missions and provides a corresponding overview of the in-space manufacturing state of the art. The latter is significantly influenced by research activities in the field of additive manufacturing, with only a few results available in the field of subtractive processing. In conclusion, a novel approach for in-situ resource utilization based subtractive manufacturing in space is presented to supplement the existing processes. The approach presented is based on a water abrasive jet process, with regolith simulate being used as the abrasive to separate metal and glass.