Carbonyl Metals Plant
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In the Mond process, carbon monoxide combines with Nickel at 50-60 C to form nickel tetracarbonyl gas. This removes nickel from impurities, none of which form a carbonyl at such a low temperature. Heating nickel tetracarbonyl to 220-250 C decomposes it into pure nickel and carbon monoxide. Various other metal carbonyls such as Iron pentacarbonyl and Chromium hexacarbonyl form at various temperatures and pressures, giving the possibility for separating pure metals from mixtures. Nickel can be deposited on an object that is heated to the nickel tetracarbonyl decomposition temperature in the presence of the gas; with a similar possibility for other metal carbonyl systems.
Metal objects can be manufactured in much the same way as plastic pieces are printed on a RepRap 3D printer. In the case of the carbonyl metals plant, printing takes place on a metal, ceramic, or regolith base in a metal carbonyl atmosphere. Using a laser, portions of the printing base are heated to high temperature which results in a breakdown of metal carbonyl at those locations. Metals are deposited and CO ligands are released. After the initial metal layer is deposited, the laser can be used to heat the previous layer and print new layers on top. Once deposition printing has been completed, the disposable base can be broken off of the metal part and the piece is ready for further finishing.
