Resistance Welding of Carbon Fiber Reinforced Thermoplastic Composites for Repurposable Applications

The investigation team is proposing to develop resistance welding of carbon fiber reinforced thermoplastic composites (TPCs) specifically for repurposable aerospace applications. The proposed innovation addressed the requirements of 2023 Phase 1 Topic T12.09 seeking to exploit unique properties of thermoplastic composites to assess their feasibility and propose concepts of operations for in situ repurposing of primary and secondary spacecraft structures into deep space exploration infrastructure supporting sustainable human presence beyond low Earth orbit (LEO). For example, the landing strut of a descent stage exploration vehicle can be repurposed as an antenna, habitat structure, or solar panel towers, allowing NASA to address the challenges of expensive up-mass. A qualified and intelligent handheld joining unit and kit for astronauts will be significant for NASA as it will accelerate the feasibility of repurposing materials in space, contributing to a more sustainable space exploration effort. During Phase I the team successfully demonstrated the developed bench top compact weld unit and performed TPC welds with innovative heating elements to obtain high lap shear strength. Building on the success of the Phase 1 effort, the team is proposing to deliver at the end of Phase II an intelligent weld unit with feedback loop requiring minimal crew participation. This will be achieved by (1) expanding the material portfolio to other reinforced thermoplastics and optimizing specific weld parameters, (2) quantifying mechanical properties as a function of cooling rate and lunar and martian thermal extreme boundary conditions, (3) optimizing Z pin and other innovative mesh heating element configuration and surface treatment to maximize mechanical properties, and (4) designing and building an intelligent hand held weld unit and associated weld kit for several thermoplastics that can be subjected to NASA flight qualification procedures. We are proposing an innovative and intelligent handheld resistance welding unit for repurposing reinforced thermoplastic composites (TPCs) encompassing space and terrestrial applications. This innovation addresses the 2023 Phase 1 Topic T12.09 that was ‘aiming to exploit unique properties of thermoplastic composites for in situ repurposing of spacecraft structures into deep space exploration infrastructure, supporting sustainable human presence beyond low Earth orbit (LEO)’. The proposal highlights the significance of in-space repurposing of materials. For example, the landing strut of a descent stage vehicle can be repurposed as an antenna or load-bearing habitat structures, addressing the challenges of expensive up-mass of up to $10K per Kg. Given the global plastic waste crisis with only 5-6% recycling, a handheld joining unit for terrestrial application will address the urgent need for tackling plastic pollution. To the best of our knowledge, such an intelligent handheld unit for joining high performance TPCs, and meeting on-site and on-demand needs, currently do not exist. The primary objective during Phase II is to mature and complete a space qualifiable and process optimized hand-held welding unit by (1) expanding the material portfolio to other reinforced thermoplastics and optimizing specific weld parameters, (2) quantifying mechanical properties as a function of cooling rate and degree of crystallinity using realistic lunar and martian thermal extreme boundary conditions, (3) understanding the effect of gravity on defect location and distribution, (4) optimizing Z pin and mesh heating element configuration and surface treatment to maximize mechanical properties, (5) introduce feedback loop  into hand-held such that the welding process will require minimal crew participation. The final deliverable to NASA will include an intelligent weld unit with feedback loop and associated weld kit for several thermoplastics that can be subjected to NASA flight qualification procedure such as vibration and electromagnetic induction testing. The deliverable package will also include statistically relevant mechanical properties of several welded TPCs, video instructions on use of welding unit, and welded samples of different thermoplastics and configurations.

For example, the landing strut of a descent stage exploration vehicle can be repurposed as an antenna, habitat structure, or solar panel towers, allowing NASA to address the challenges of expensive up-mass. This investigation highlights the significance of in-space repurposing of materials by developing a qualified and intelligent handheld joining unit and kit for astronauts. This is significant for NASA as it will accelerate the feasibility of repurposing materials in space, contributing to a more sustainable space exploration effort. Thermoplastic composites are booming in markets that include infrastructure products (lumber, utility, decking, coastline), sporting goods, automotive, and construction. Advanced thermoplastic fiber composites are a growing and integral part of these markets. There are immediate opportunities for the proposed joining technology in each of these sectors.

This is early/mid-stage (TRL 5) — 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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