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NASA NTRS1972

Ultrasonic thermometry using pulse techniques.

Ultrasonic pulse techniques have been developed which, when applied to inert gases, provide temperature measurements up to 8000 K. The response time can be less than 1 msec. This is a significant feature in studying shock-heated or combusting gases. Using a momentary contact coupling technique, temperature has been measured inside steel from 300 to 1500 K. Thin-wire sensors have been used above 2000 K in nuclear and industrial applications where conditions preclude the use of thermocouples, resistance devices, or optical pyrometers. At 2500 K, temperature sensitivity of 0.1% is obtained in Re wire sensors 5 cm long by timing five round trips with an electronic instrument that resolves the time interval between selected echoes to 0.1 microsec. Sensors have been operated at rotational speeds over 2000 rpm and in noisy environments. Temperature profiling of up to ten regions using only a single guided path or beam has also been accomplished.

Lynnworth, L. C.↗

DOE OSTI2010

BPM Design and Impedance Considerations for a Rotatable Collimator for the LHC Collimation Upgrade

The Phase II upgrade to the LHC collimation system calls for complementing the 30 high robust Phase I graphite secondary collimators with 30 high Z Phase II collimators. This paper reports on BPM and impedance considerations and measurements of the integrated BPMs in the prototype rotatable collimator to be installed in the Super Proton Synchrotron (SPS) at CERN. The BPMs are necessary to align the jaws with the beam. Without careful design the beam impedance can result in unacceptable heating of the chamber wall or beam instabilities. The impedance measurements involve utilizing both a single displaced wire and two wires excited in opposite phase to disentangle the driving and detuning transverse impedances. Trapped mode resonances and longitudinal impedance are to also be measured and compared with simulations. These measurements, when completed, will demonstrate the device is fully operational and has the impedance characteristics and BPM performance acceptable for installation in the SPS.

43 PARTICLE ACCELERATORS↗

NASA NTRS1983

Stability experiments in rotating-disk flow

An experimental study of the transitional flow on a flat disk, rotating in still air, has been conducted. Using digitized hot-wire data, the axes of the stationary spiral vortices, which are the primary instability mechanism for the disk flow, have been mapped-out in terms of both spatial coordinates and velocity fluctuations. Data are presented for a clean disk and for a disk with a single, isolated roughness element. The data show that the disk vortices are generated at discrete roughness disturbance sites on the disk and that they propagate and grow as wave packets. The familiar vortex pattern of 30 or so vortices results only when these wave packets have merged and filled the entire circumference. The appearance of stationary, secondary vortices prior to turbulent breakdown has also been observed. Comparisons with linear stability theory show reasonable agreement with measured growth rate data.

Wilkinson, S. P.↗

DOE OSTI2024

Topological Kondo effect with spinful Majorana fermions

Motivated by the importance of studying topological superconductors beyond the mean-field approximation, we here investigate mesoscopic islands of time-reversal-invariant topological superconductors. We characterize the spectrum in the presence of strong order-parameter fluctuations in the presence of an arbitrary number of Kramers pairs of Majorana edge states and study the effect of coupling the Coulomb blockaded island to external leads. In the case of an odd fermionic parity on the island, we derive an unconventional Kondo Hamiltonian in which metallic leads couple to both topological Majorana degrees of freedom (which keep track of the parity in different leads) and the overall spin 1 2 in the island. For the simplest case of a single wire (two pairs of Majorana edge states), we demonstrate that anisotropies are irrelevant in the weak coupling renormalization group flow. This permits us to solve the Kondo problem in the vicinity of a Toulouse-type point using Abelian bosonization. We demonstrate a residual ground-state entropy of ln ( 2 ) , which is protected by spin-rotation symmetry, but reduced to ln ( 2 ) (as in the spinless topological Kondo effect) by symmetry-breaking perturbations. In the symmetric case, we further demonstrate the simultaneous presence of both Fermi-liquid and non-Fermi-liquid-like thermodynamics (depending on the observable) and derive charge and spin transport signatures of the Coulomb blockaded island. Published by the American Physical Society 2024

Materials Science↗

NASA NTRS2000

Experimental Study of the Structure of a Wingtip Vortex

A complete look at the near-field development and subsequent role-up of a wingtip vortex from a NACA 0015 wing section is investigated. Two separate but equally important surveys of the vortex structure in the region adjacent to the wingtip and approximately one chord length downstream of the trailing edge are performed. The two surveys provide qualitative flow-visualization an quantitative velocity measurement data. The near-field development and subsequent role-up of the vortex structures is strongly influenced by the angle-of-attack and the end-cap treatment of the wing section. The velocity field near the wingtip of the NACA 0015 wing section was measured with a triple-sensor hot wire probe and compared to flow visualization images produced with titanium tetrachloride smoke injection and laser illumination. The flat end-cap results indicate the formation of multiple, relatively strong vortex structures as opposed to the formation of a single vortex produced with the round end-cap. The multiple vortices generated by the flat end-cap are seen to rotate around a common ce te in a helical pattern until they eventually merge into a single vortex. Compared to a non-dimensional loading parameter, the results of the velocity and flow visualization data shows a "jetlike" axial velocity profile for loading parameter values on the order of 0.1 and a "wakelike" profile for much lower loading parameter values.

Anderson, Elgin A.↗

DOE OSTI2025

A new tubular ironless linear induction motor using non-interrupted winding method

The ironless linear induction motor device can be used for any application which requires a large motion span or rotation restrictedly by the ironless feature due to the strong magnetic field environment. One of the possible applications is ITER diagnostics shutters. The tokamak reactor systems have a severe radiation issue during the operation. The traditional Kapton-insulated wires have significantly lower radiation resistance than an expected large radiation dose at ITER Motion Stark Effect (MSE) shutter location. Furthermore, the traditional single-sided linear induction motor winds the wire to make the N-turn pitch coils independently and then connect them in series to make a one-phase winding. Therefore, it is a big challenge to make so many radiation-protection connectors in such a limited space as inside the vacuum vessel of fusion reactors. The approved mineral-insulated kinds of cables need a large bend radius for the end turns, so the traditional single-sided linear motor with two-layer three-phase windings need to be upgraded to the tubular linear motors. The new proposed tubular ironless linear induction motor can not only overcome the large bend radius issue with the mineral-insulated cables but also allow the motor coils wound continuously around the tubular-shaped stator, forward and backward N times to make a N-turn winding for each phase, in order to resolve the radiation protection issue with the winding connection. The 3D transient Maxwell electromagnetic model with a tubular three-phase linear induction motor has been analyzed. Furthermore, this paper will present the detailed design and winding method of ironless linear induction motor actuators, and results of the 3D transient numerical simulation of the actuator performance.

Ironless↗

NASA NTRS1959

Performance of Typical Rear-Stage Axial-Flow Compressor Rotor Blade Row at Three Different Blade Setting Angles

A comparison of the performance of a single-stage rotor run at three different blade setting angles is presented. The rotor was of a design typical for a last stage of a multistage compressor. At each setting angle, the rotor blade row was operated from 53 to 100 percent of equivalent maximum speed (850 ft/sec tip speed) at constant inlet pressure. Hot-wire anemometry was used to observe rotating-stall and surge patterns in time unsteady flow. Results indicated that an increase in peak pressure ratio and an increase in maximum equivalent weight flow were obtained at each speed investigated when the blade setting angle was decreased. An increase in peak efficiency was achieved with decrease in blade setting angle for part of the range of speeds investigated. However, the peak efficiencies for the three blade setting angles were approximately the same at the maximum speed investigated. The flow ranges for all three configurations were about the same at minimum speed and decreased at almost the same rate when the rotative speed was increased through part of the range of speeds investigated. At maximum speed, the flow range for the smallest setting angle was considerably less than the flow range for the other two configurations. A decrease in efficiency and flow range for the smallest blade setting angle at maximum speed can be attributed primarily to a Mach number effect. In addition, because of the difference in projected axial chord lengths at the casing wall, some effect on performance could be expected from the change in three-dimensional flow occurring at the tip. Rotating-stall characteristics for the two smaller blade setting angles were essentially the same. Only surge could be detected for the largest blade setting angle in the unstable-flow region of operation.

Kussoy, Marvin I.↗

NASA NTRS1997

The Spectral and Statistical Properties of Turbulence Generated by a Vortex/Blade-Tip Interaction

The perpendicular interaction of a streamwise vortex with the tip of a lifting blade was studied in incompressible flow to provide information useful to the accurate prediction of helicopter rotor noise and the understanding of vortex dominated turbulent flows. The vortex passed 0.3 chord lengths to the suction side of the blade tip, providing a weak interaction. Single and two-point turbulence measurements were made using sub-miniature four sensor hot-wire probes 15 chord lengths downstream of the blade trailing edge; revealing the mean velocity and Reynolds stress tensor distributions of the turbulence, as well as its spanwise length scales as a function of frequency. The single point measurements show the flow downstream of the blade to be dominated by the interaction of the original tip vortex and the vortex shed by the blade. These vortices rotate about each other under their mutual induction, winding up the turbulent wakes of the blades. This interaction between the vortices appears to be the source of new turbulence in their cores and in the region between them. This turbulence appears to be responsible for some decay in the core of the original vortex, not seen when the blade is removed. The region between the vortices is not only a region of comparatively large stresses, but also one of intense turbulence production. Velocity autospectra measured near its center suggests the presence quasi-periodic large eddies with axes roughly parallel to a line joining the vortex cores. Detailed two-point measurements were made on a series of spanwise cuts through the flow so as to reveal the turbulence scales as they would be seen along the span of an intersecting airfoil. The measurements were made over a range of probe separations that enabled them to be analyzed not only in terms of coherence and phase spectra but also in terms of wave-number frequency (kappa-omega) spectra, computed by transforming the measured cross-spectra with respect to the spanwise separation of the probes. These data clearly show the influence of the coherent eddies in the spiral wake and the turbulent region between the cores. These eddies produce distinct peaks in the upwash velocity kappa-omega spectra, and strong anisotropy manifested both in the decay of the kappa-omega spectrum at larger wave-numbers and in differences between the kappa-omega spectra of different components. None of these features are represented in the von Karman spectrum for isotropic turbulence that is often used in broadband noise computations. Wave-number frequency spectra measured in the cores appear to show some evidence that the turbulence outside sets tip core waves, as has previously been hypothesized. These spectra also provide for the first time a truly objective method for distinguishing velocity fluctuations produced by core wandering from other motions.

Devenport, William J.↗

DOE OSTI2013

A dual cone-beam CT system for image guided radiotherapy: Initial performance characterization

Purpose: The purpose of this study is to evaluate the performance of a recently developed benchtop dual cone-beam computed tomography (CBCT) system with two orthogonally placed tube/detector sets. Methods: The benchtop dual CBCT system consists of two orthogonally placed 40 Multiplication-Sign 30 cm flat-panel detectors and two conventional x-ray tubes with two individual high-voltage generators sharing the same rotational axis. The x-ray source to detector distance is 150 cm and x-ray source to rotational axis distance is 100 cm for both subsystems. The objects are scanned through 200 Degree-Sign of rotation. The dual CBCT system utilized 110 Degree-Sign of projection data from one detector and 90 Degree-Sign from the other while the two individual single CBCTs utilized 200 Degree-Sign data from each detector. The system performance was characterized in terms of uniformity, contrast, spatial resolution, noise power spectrum, and CT number linearity. The uniformities, within the axial slice and along the longitudinal direction, and noise power spectrum were assessed by scanning a water bucket; the contrast and CT number linearity were measured using the Catphan phantom; and the spatial resolution was evaluated using a tungsten wire phantom. A skull phantom and a ham were also scanned to provide qualitative evaluation of high- and low-contrast resolution. Each measurement was compared between dual and single CBCT systems. Results: Compared to single CBCT, the dual CBCT presented: (1) a decrease in uniformity by 1.9% in axial view and 1.1% in the longitudinal view, as averaged for four energies (80, 100, 125, and 150 kVp); (2) comparable or slightly better contrast (0{approx}25 HU) for low-contrast objects and comparable contrast for high-contrast objects; (3) comparable spatial resolution; (4) comparable CT number linearity with R{sup 2}{>=} 0.99 for all four tested energies; (5) lower noise power spectrum in magnitude. Dual CBCT images of the skull phantom and the ham demonstrated both high-contrast resolution and good soft-tissue contrast. Conclusions: The performance of a benchtop dual CBCT imaging system has been characterized and is comparable to that of a single CBCT.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

New large-strain FFT-based formulation and its application to model strain localization in nano-metallic laminates and other strongly anisotropic crystalline materials

This paper presents a new robust large-strain (LS) elasto-viscoplastic (EVP) formulation based on Fast Fourier Transforms (FFTs) for the prediction of the micro-mechanical response and microstructure evolution of polycrystalline and multiphase materials, with emphasis on the effect of strong crystallographic and/or morphologic anisotropy on localization of plastic deformation. In this work, the novel LS-EVPFFT formulation allows treatment of complex initial geometries and large deformations considering three grids of material points: a regular grid in the reference configuration, where FFTs can be performed; an irregular grid in the initial configuration, created by applying a stress-free displacement field to the reference regular grid; and an irregular grid in the current configuration, undergoing large strains and rotations as the material is loaded. Further numerical stability of the new formulation also required the use of a novel expression for the discrete modified Green’s operator, which reduces spurious field oscillations. After presenting and validating the new formulation by comparison with preexisting implementations and analytical solutions, LS-EVPFFT is applied to the prediction of slip and kink bands formation in polycrystalline columnar ice, and kink bands in single crystal zinc wires, showing good agreement with classic experiments. Finally, the model is used to study kink band formation during compression of Cu–Nb nano-metallic laminates (NMLs), in which accurate treatment of the complex geometry associated with the tortuosity of interfaces and large deformations become critical, showing consistency with corresponding micropillar experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Fabrication of single crystalline, uniaxial single domain Co nanowire arrays with high coercivity

Whilst Co nanorods with high coercivity were synthesized during recent years, they did not achieve the same results as for Co nanowires embedded in solid templates. In the present work, Co nanowire arrays (NWAs) with high coercivity were successfully fabricated in porous aluminum oxide template under optimum conditions by using pulsed ac electrodeposition technique. Magnetic properties and crystalline characteristics of the nanowires were investigated by hysteresis loop measurements, first-order reversal curve (FORC) analysis, X-ray diffraction (XRD), and selected area electron diffraction (SAED) patterns. Hysteresis loop measurements showed high coercivity of about 4.8 kOe at room temperature together with optimum squareness of 1, resulting in an increase of the previous maximum coercivity for Co NWAs up to 45%. XRD and SAED patterns revealed a single crystalline texture along the [0002] direction, indicating the large magnetocrystalline anisotropy. On the other hand, FORC analysis confirmed a single domain structure for the Co NWAs. In addition, the reversal mechanism of the single crystalline, single domain Co NWAs was studied which resulted in the fixed easy axis with a coherent rotation. Accordingly, these nanowires might offer promising applications in high density bit patterned media and low power logic devices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1992

Structure of a swirling turbulent mixing layer

A single-stream swirling turbulent mixing layer was produced in which the angular momentum instability acts over most of the layer for most of its development length. The instability is associated with a large increase in the level of the conventional Reynolds stresses over those in an unswirled mixing layer. This paper presents measurements of the three-dimensionality of the mean flow at one axial location well downstream of the origin. The output of a fixed hot-wire probe was ensemble-averaged to produce an approximation to the mean flow field that would be seen by a rotating observer. The main goals of this study were to establish the presence or absence of Taylor-Goertler vortices found in unstable laminar boundary layers. The variations in the mean velocities and Reynolds stresses are generally consistent with a bodily 'wrinkling' of the mixing layer, without a significant variation in the layer thickness. The wrinkling is most probably a result of circumferential variations in the initial boundary layer, which in turn originate at the swirl generator.

Wood, D. H.↗

DOE OSTI2013

Lattice dependent motion of voids during electromigration

The influence of the crystal lattice configuration to electromigration processes, e.g., void formation and propagation, is investigated in suitable test structures. They are fabricated out of self-assembled, bi-crystalline Ag islands, grown epitaxially on a clean Si(111) surface. The {mu}m-wide and approximately 100 nm thick Ag islands are a composition of a Ag(001) and a Ag(111) part. By focused ion beam milling, they are structured into wires with a single grain boundary, the orientation of which can be chosen arbitrarily. In-situ scanning electron microscopy (SEM) allows to capture an image sequence during electrical stressing and monitors the development of voids and hillocks in time. To visualize the position and motion of voids, we calculate void maps using a threshold algorithm. Most of the information from the SEM image sequence is compressed into one single image. Our present electromigration studies are based on in-situ SEM investigations for three different lattice configurations: Ag(001) (with electron current flow in [110] direction), Ag(111) (with electron current flow in [112] direction), and additionally 90 Ring-Operator rotated Ag(111) (with electron current flow in [110] direction). Our experimental results show that not only the formation and shape but also the motion direction of voids strongly depends on the crystal orientation.

36 MATERIALS SCIENCE↗

DOE OSTI2011

Process for anodizing a robotic device

A robotic device has a base and at least one finger having at least two links that are connected in series on rotary joints with at least two degrees of freedom. A brushless motor and an associated controller are located at each joint to produce a rotational movement of a link. Wires for electrical power and communication serially connect the controllers in a distributed control network. A network operating controller coordinates the operation of the network, including power distribution. At least one, but more typically two to five, wires interconnect all the controllers through one or more joints. Motor sensors and external world sensors monitor operating parameters of the robotic hand. The electrical signal output of the sensors can be input anywhere on the distributed control network. V-grooves on the robotic hand locate objects precisely and assist in gripping. The hand is sealed, immersible and has electrical connections through the rotary joints for anodizing in a single dunk without masking. In various forms, this intelligent, self-contained, dexterous hand, or combinations of such hands, can perform a wide variety of object gripping and manipulating tasks, as well as locomotion and combinations of locomotion and gripping.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Chiral twisted van der Waals nanowires

Van der Waals heterostructures with small misalignment between adjacent layers (‘interlayer twist’) are of interest because of electronic structure and correlation phenomena (such as superconductivity) that are determined by both the atomic lattice and long-range superlattice potentials arising in interlayer moiré patterns. Previously, such twisted heterostructures have involved a single planar interface between layers isolated by exfoliation and micromechanically stacked in the desired relative orientation. Here we demonstrate a class of materials—van der Waals nanowires of layered crystals—in which a tunable interlayer twist evolves naturally during synthesis. In vapour–liquid–solid growth, nanowires of germanium(ii) sulfide, an anisotropic layered semiconductor, crystallize with layering along the wire axis and have a strong propensity for forming axial screw dislocations. Nanometre-resolved electron diffraction shows that Eshelby twist, induced by a torque on the ends of a cylindrical solid due to the stress field of an axial dislocation, causes a chiral structure in the van der Waals nanowires. The in-plane germanium sulfide crystal axes progressively rotate along the wire, and germanium sulfide layers in adjacent turns of the helix naturally form a moiré pattern because of their interlayer twist. The axial rotation and the twist are tunable by varying the nanowire thickness. Combined electron diffraction and cathodoluminescence spectroscopy show the correlation between the interlayer twist and locally excited light emission that is due to progressive changes in the lattice orientation and in the interlayer moiré registry along the nanowires. Furthermore, the findings demonstrate a step towards scalable fabrication of van der Waals structures with defined twist angles, in which interlayer moiré patterns are realized along a helical path on a nanowire instead of a planar interface.

36 MATERIALS SCIENCE↗

DOE OSTI2019

R and DE Robotic Sensor Intern Team: Sensor Suite Mock Up Testing

Assess sensor suite performance: - Mounted on crawler typical to what would be used in tunnel; - In test bed simulating the tunnel environment. The SuperDroid fiber tethered LT-F crawler is a general-purpose surveillance robot that our team has refurbished as a testing platform for the sensor suite. This crawler was selected because its dimensions are similar to the actual crawler that will be deployed in the field. Crawler preparation included: - Communicating with vendor to resolve software and platform issues; - Configuring a laptop with the crawler control software; - Reconfiguration of communication protocol between computer and crawler; - Resolution of control board checksum errors; - Installation of a mounting fixture on the base; - In progress: addition of lighting needed for total darkness. A solution for hosting the selected sensors onto a single unit that could function standalone or be mounted on the crawler was needed. Sensor mount requirements included: - Host Lidar, panospheric cameras and IMU sensors; - Cable management for rotating Lidar; - House on-board crawler computer; - Method for affixing to crawler; - Robust and vibration proof. The Lidar sensor required a sturdy mount that ensured the axis of rotation be centered with the LiDAR's desired laser path and included a slender profile in order to not block the scanning FOV. The mounting plate holds two 180-degree cameras on either side and the servo on the center. The servo mount is located so the axis of rotation is in the center of the plate. The mount features a set of guides that hold the wires and ensure they wrap around the spool area properly. The sensor box design features thick walls for added strength, holes for mounting the sensor suite to the crawler, notches on the bottom for the different components and holes for cable routing and management. The sensor mounts were designed using CREO and printed in the R and DE Additive Manufacturing Lab. To test the performance of the sensor suite for our application it was desired to design and build a test bed simulating the H-Canyon tunnel environment. Requirements included: - Dimensions similar to the tunnel; - Wall surfaces simulating the eroded tunnel walls; - Complete darkness; - Even and uneven crawler path; - Ability to change the tunnel width to simulate erosion. The HCAEX tunnel changes in height and includes several bends ranging from approximately 30 to 80 degrees, for that reason a test bed capable of easily being changed was needed. The final design includes two sections that can be connected to provide a 16' tunnel or placed at an angle to create a tunnel bend. The test bed features caster wheels for easy movement and has a sliding inner wall that enables tunnel width to be controlled. In order to simulate the tunnel walls without adding a lot of weight to the test bed, sheets of faux stone are to be used on the inner walls. To create a completely dark tunnel, 100% black-out film will be draped over the tunnel structure. Carpet remnants in the lab will enable folds to be introduced in the floor to generate uneven surface data.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

Possible Dynamically Gated Conductance along Heme Wires in Bacterial Multiheme Cytochromes

The staggered cross decaheme configuration of electron transfer co-factors in the outer-membrane cytochrome MtrF may serve as a prototype for conformationally-gated multi-heme electron transport. Derived from the bacterium Shewanella oneidensis, the staggered cross configuration reveals intersecting c-type octaheme and tetraheme “wires” containing thermodynamic “hills” and “valleys”, suggesting that the protein structure may include a dynamical mechanism for conductance and pathway switching depending on enzymatic functional need. Recent molecular simulations have established the pair-wise electronic couplings, redox potentials, and reorganization energies to predict the maximum conductance along the various heme wire pathways by sequential hopping of a single electron (PNAS (2014) 11,611-616). Here, we expand this information with classical molecular and statistical mechanics calculations of large-amplitude protein dynamics in MtrF, to address its potential to modulate pathway conductance, including assessment of the effect of the total charge state. Explicit solvent molecular dynamics simulations of fully oxidized and fully reduced MtrF employing ten independent 50-ns simulations at 300 K and 1 atm showed that reduced MtrF is more expanded and explores more conformational space than oxidized MtrF, and that heme reduction leads to increased heme solvent exposure. The slowest mode of collective decaheme motion is 90% similar between the oxidized and reduced states, and consists primarily of inter-heme separation with minor rotational contributions. The frequency of this motion is 1.7×107 s 1 for fully-oxidized and fully-reduced MtrF, respectively, slower than the downhill electron transfer rates between stacked heme pairs at the octaheme termini and faster than the electron transfer rates between parallel hemes in the tetraheme chain. This implies that MtrF uses slow conformational fluctuations to modulate electron flow along the octaheme pathway, apparently for the purpose of increasing the residence time of electrons on lowest potential hemes 4 and 9. This apparent gating mechanism should increase the success rate of electron transfer from MtrF to low potential environmental acceptors via these two solvent-exposed hemes.

c-type cytochromes, MtrF, Shewanella oneidensis, h↗

NASA NTRSDate not supplied

Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing

NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.

Manufacturing↗