Integrated Computational Materials Engineering (ICME) for In-Space and Extraterrestrial Surface Metal Welding and Joining

Despite the maturity of welding and related joining processes for terrestrial applications, there is limited understanding of the effects of an in-space environment on weld quality. An Integrated Computational Materials Engineering (ICME) framework leveraging physics-based process and metallurgical models , anchored by terrestrial and flight data, is desired to predict the effects of in-space, lunar, and Martian environments on the welding process and resulting material properties. To address this need, CFD Research will establish critical elements of such a framework, namely physics-based welding process models to evaluate the relevant environmental effects (microgravity, vacuum, extreme ambient temperature), and grain structure evolution models addressing both fusion from the melt and coarsening in the heat affected zone. During the Phase I effort, models for evaporation effects on the weld melt pool were evaluated and a compact, efficient approach to incorporating these effects into multiphysics welding process simulations was developed. Additional model components necessary for such simulations to address in-space laser welding were identified, and weld pool state information was used to predict the solidification microstructure. In this Phase II effort, CFD Research will adapt and validate software to fill the remaining gaps in an ICME framework for in-space welding process developers, establish data transfer to link melt pool scale welding simulations with prediction of the resulting grain structure, and validate the linked software against historical and upcoming flight data. Application studies will be performed to develop and mature the simulation and analysis workflow, followed by documentation and delivery of the resulting software and test cases to NASA. Welding and joining in-space are expected to increase in importance for NASA, particularly for assembly and repairs at Gateway and future orbiting stations. Confidence in in-space joining will remove launch load constraints and enable larger, more complex systems. Demonstrated, mature in-space welding and joining technology has been identified by NASA and commercial partners as a capability that will have broad application in the emerging LEO economy. However, only a very limited number of experiments have been performed to evaluate welding processes in an in-space environment. An ICME framework that captures the effects of the in-space processing environment on the process will contribute to analysis of upcoming demonstration efforts and application of the resulting information. This effort will fill remaining gaps in an ICME toolkit for welding process development and maturation, leveraging terrestrial and upcoming flight data for validation, and enable confident welding process development and insertion.  The overall technical objective of this effort is to provide validated ICME tools to address the effects of in-space, lunar, and Martian environments on welding and related joining processes. Specifically: 1 Verify and validate melt pool scale welding process models for in-space (vacuum, microgravity, extreme ambient temperature) analysis; 2 Provide a grain growth simulation tool for the weld microstructure in both the fusion zone and the heat affected zone; 3 Link the melt pool and grain growth models for integrated weld process analysis; and 4 Provide the resulting ICME tools and analysis workflow to NASA for application to in-space weld process development. To meet these objectives, we will 1 Adapt melt pool scale welding process models for in-space processing; test, and validate against upcoming flight data; 2 Develop and validate a grain growth simulation tool for the weld microstructure in both the fusion zone and the heat affected zone; 3 Link the melt pool and grain growth models and validate against flight and relevant terrestrial data; 4 Mature the workflow through application studies, document and transfer the resulting tools for NASA application to in-space weld process development.   Deliverables will include all developed software, and reports documenting methods and results.

Welding and joining processes are critical technologies for in-space manufacturing and repair at Gateway, other future orbiting stations, and sustained lunar presence. Confidence in the performance of in-space joining processes will enable NASA and commercial firms developing orbiting infrastructure to circumvent the launch load and payload fairing constraints on large structures such as in-space habitats, reduce technical risk, and optimize payload packaging efficiency to launch system components. The commercial market for in-space application of this ICME framework will strongly overlap the anticipated NASA applications for space-based manufacturing and repair. The proposed tools can accelerate both learning from recently announced in-space welding demonstrations, and the transition to routine application. The developed capabilities will also benefit in-space metal additive manufacturing.

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