Laser Beam Welding in Thermal Vacuum and in Microgravity to Mature In-Space Welding

The broadening of the in-space economy and expansion of space exploration activities necessitates a suitable joining method for in-space manufacturing and repair of metallic structures. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on in-space welding is not yet fully elucidated. Two primary efforts led by NASA Marshall Space Flight Center are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum and combined vacuum & reduced gravity environments.

The first is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). This project has partnered with Laserline, Inc. to demonstrated ruggedized LBW optics and delivery fiber in a thermal vacuum environment. Additional work is progressing on weld inspection via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). NASA Johnson Space Center is partnered with both Motiv Space Systems, Inc. and PickNik, Inc. to advance supervised autonomy of a ruggedized robotic manipulator. NASA Langley Research Center is modifying their unique snowflake joint geometry for Lunar infrastructure to make it suitable for welding.

The second effort is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which is developing experimental hardware capable of supporting in-space manufacturing and other technology development efforts and is adaptable to multiple flight platforms. The first technology will be LBW, and the first flight platform is anticipated to be a parabolic aircraft. The DISCMAN is intended to mature into process development of LBW on orbital or suborbital platforms; such platforms allow access to longer duration, higher quality low gravity environments. Thus, LASAR investigates temperature and vacuum on LBW while DISCMAN investigates vacuum and gravity on LBW.