Reduced-Gravity Laser Welding Experiment to Enable Maturation of Computational Models and Process

The Reduced-Gravity Laser Welding Experiment to Enable Maturation of Computational Models and Process supports the development of welding in space and on the lunar surface by testing laser welding technology in parabolic flight. Researchers will collect critical process and material data to calibrate and validate computational models of the welding process under variable gravity conditions and in vacuum. Laser welding is a compact and flexible solution for manufacturing, assembly, and repair in space that can support the growing space economy by facilitating the assembly of large structures and providing robust repair methods that enable long-term sustained human presence in space. 

Problem Statement Welding is used to make approximately 90% of durable goods produced on Earth and is an enabling technology for the Earth-based manufacturing of space flight hardware. Welding and allied technologies such as cutting, surface cleaning, heat treating, and 3D printing are critical for manufacturing, assembly, and repair in space and on the lunar surface. While methods for soldering, brazing, and solidification of metals in low Earth orbit (LEO) have previously been investigated, data on welding in microgravity is lacking. Compact and power-efficient welding and joining processes are essential, especially those capable of working with a variety of metals and alloys. Aluminum alloys, stainless steels, and titanium alloys, widely used in spacecraft, will demand versatile welding capabilities.

Technology Maturation Parabolic flight tests will help researchers identify the physical and metallurgical changes that occur when shifting from welding on Earth to the space environment. Welding is a complex physical process that involves extreme temperature gradients and multiple phases of matter over short timescales. This complexity necessitates extensive development cycles to realize robust Earth-based hardware for use in space. Such development is currently not possible in space due to lack of orbital welding platforms. The flight tests aim to advance the technology readiness level (TRL) to TRL 6. 

Summary of August 20, 2024 Flight Test
The team performed the first ever demonstration of high-power fiber laser beam welding under high vacuum and micro- and lunar gravity conditions. In situ temperature metrology and weld pool characterization and ex situ metallurgical characterization are combined to create the first validation dataset of its kind. This dataset will anchor computational models that will enable one-shot critical laser beam welds in space and on the lunar surface. Development of this welding technology will be crucial to manufacturing, assembly, and repair ensuring longterm sustainability between the Earth, Moon, and Mars.
 

- Capable: Overcomes launch platform size constraints by supporting in-space welding. 
- Robust: Provides repair methods that enable long-term sustained human presence in LEO, the lunar surface, and beyond. 

Future Customers 
In-space welding will enable In-space Servicing, Assembly and Manufacturing (ISAM) applications including: 
- In-space structures and habitats (e.g. trusses, antennas, solar arrays, sunshades, radiators) 
- Lunar surface infrastructure

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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