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NASA NTRS1985

Solid state laser technology - A NASA perspective

NASA's program for developing solid-state laser technology and applying it to the Space Shuttle and Space Platform is discussed. Solid-state lasers are required to fulfill the Earth Observation System's requirements. The role of the Office of Aeronautics and Space Technology in developing a NASA tunable solid-state laser program is described. The major goals of the program involve developing a solid-state pump laser in the green, using AlGaAs array technology, pumping a Nd:YAG/SLAB crystal or glass, and fabricating a lidar system, with either a CO2 laser at 10.6 microns or a Nd:YAG laser at 1.06 microns, to measure tropospheric winds to an accuracy of + or - 1 m/s and a vertical resolution of 1 km. The procedures to be followed in order to visualize this technology plan include: (1) material development and characterization, (2) laser development, and (3) implementation of the lasers.

Allario, F.↗

NASA NTRS2003

A Tabletop Tool for Modeling Life Support Systems

This paper describes the development plan for a comprehensive research and diagnostic tool for aspects of advanced life support systems in space-based laboratories. Specifically it aims to build a high fidelity tabletop model that can be used for the purpose of risk mitigation, failure mode analysis, contamination tracking, and testing reliability. We envision a comprehensive approach involving experimental work coupled with numerical simulation to develop this diagnostic tool. It envisions a 10% scale transparent model of a space platform such as the International Space Station that operates with water or a specific matched index of refraction liquid as the working fluid. This allows the scaling of a 10 ft x 10 ft x 10 ft room with air flow to 1 ft x 1 ft x 1 ft tabletop model with water/liquid flow. Dynamic similitude for this length scale dictates model velocities to be 67% of full-scale and thereby the time scale of the model to represent 15% of the full- scale system; meaning identical processes in the model are completed in 15% of the full- scale time. The use of an index matching fluid (fluid that matches the refractive index of cast acrylic, the model material) allows making the entire model (with complex internal geometry) transparent and hence conducive to non-intrusive optical diagnostics. So using such a system one can test environment control parameters such as core flows (axial flows), cross flows (from registers and diffusers), potential problem areas such as flow short circuits, inadequate oxygen content, build up of other gases beyond desirable levels, test mixing processes within the system at local nodes or compartments and assess the overall system performance. The system allows quantitative measurements of contaminants introduced in the system and allows testing and optimizing the tracking process and removal of contaminants. The envisaged system will be modular and hence flexible for quick configuration change and subsequent testing. The data and inferences from the tests will allow for improvements in the development and design of next generation life support systems and configurations.

Ramachandran, N.↗

NASA NTRS2006

Magnetic Nozzle and Plasma Detachment Experiment

High power plasma propulsion can move large payloads for orbit transfer (such as the ISS), lunar missions, and beyond with large savings in fuel consumption owing to the high specific impulse. At high power, lifetime of the thruster becomes an issue. Electrodeless devices with magnetically guided plasma offer the advantage of long life since magnetic fields confine the plasma radially and keep it from impacting the material surfaces. For decades, concerns have been raised about the plasma remaining attached to the magnetic field and returning to the vehicle along the closed magnetic field lines. Recent analysis suggests that this may not be an issue of the magnetic field is properly shaped in the nozzle region and the plasma has sufficient energy density to stretch the magnetic field downstream. An experiment was performed to test the theory regarding the Magneto-hydrodynamic (MHD) detachment scenario. Data from this experiment will be presented. The Variable Specific Impulse Magnetoplasma Rocket (VASIMR) being developed by the Ad Astra Rocket Company uses a magnetic nozzle as described above. The VASIMR is also a leading candidate for exploiting an electric propulsion test platform being considered for the ISS.

Chavers, Gregory↗

NASA NTRS2005

Space Laboratory on a Table Top: A Next Generative ECLSS design and diagnostic tool

This paper describes the development plan for a comprehensive research and diagnostic tool for aspects of advanced life support systems in space-based laboratories. Specifically it aims to build a high fidelity tabletop model that can be used for the purpose of risk mitigation, failure mode analysis, contamination tracking, and testing reliability. We envision a comprehensive approach involving experimental work coupled with numerical simulation to develop this diagnostic tool. It envisions a 10% scale transparent model of a space platform such as the International Space Station that operates with water or a specific matched index of refraction liquid as the working fluid. This allows the scaling of a 10 ft x 10 ft x 10 ft room with air flow to 1 ft x 1 ft x 1 ft tabletop model with water/liquid flow. Dynamic similitude for this length scale dictates model velocities to be 67% of full-scale and thereby the time scale of the model to represent 15% of the full- scale system; meaning identical processes in the model are completed in 15% of the full- scale-time. The use of an index matching fluid (fluid that matches the refractive index of cast acrylic, the model material) allows making the entire model (with complex internal geometry) transparent and hence conducive to non-intrusive optical diagnostics. So using such a system one can test environment control parameters such as core flows (axial flows), cross flows (from registers and diffusers), potential problem areas such as flow short circuits, inadequate oxygen content, build up of other gases beyond desirable levels, test mixing processes within the system at local nodes or compartments and assess the overall system performance. The system allows quantitative measurements of contaminants introduced in the system and allows testing and optimizing the tracking process and removal of contaminants. The envisaged system will be modular and hence flexible for quick configuration change and subsequent testing. The data and inferences from the tests will allow for improvements in the development and design of next generation life support systems and configurations. Preliminary experimental and modeling work in this area will be presented. This involves testing of a single inlet-exit model with detailed 3-D flow visualization and quantitative diagnostics and computational modeling of the system.

Ramachandran, N.↗

NASA NTRS2011

Ndarts

Ndarts software provides algorithms for computing quantities associated with the dynamics of articulated, rigid-link, multibody systems. It is designed as a general-purpose dynamics library that can be used for the modeling of robotic platforms, space vehicles, molecular dynamics, and other such applications. The architecture and algorithms in Ndarts are based on the Spatial Operator Algebra (SOA) theory for computational multibody and robot dynamics developed at JPL. It uses minimal, internal coordinate models. The algorithms are low-order, recursive scatter/ gather algorithms. In comparison with the earlier Darts++ software, this version has a more general and cleaner design needed to support a larger class of computational dynamics needs. It includes a frames infrastructure, allows algorithms to operate on subgraphs of the system, and implements lazy and deferred computation for better efficiency. Dynamics modeling modules such as Ndarts are core building blocks of control and simulation software for space, robotic, mechanism, bio-molecular, and material systems modeling.

Jain, Abhinandan↗

NASA NTRSDate not supplied

On The Incorporation of Both Function-Driven Requirements and Topology Optimization in The Development of Lunar Launch & Landing Pads

In the design of additively manufactured structures, there can be a constant battle between focusing on function-driven design and topology optimization in an attempt to improve a products ability to meet all requirements. Function-driven optimization is defined as the process of identifying the best design parameters that satisfy project functionality requirements. Function-driven optimization is typically implemented by a designer(s) who, instead of computational limitations, has human bias for the input or inputs determined. On the other hand, topology optimization is defined as a mathematical method that optimizes material layout within a given design space, for a given set of loads, boundary conditions, and constraints with the goal of maximizing the performance of the system. In topology optimization, the work is defined by the limited mathematical inputs and computationally available goals/restraints. If not evaluated simultaneously, these two approaches can result in fundamentally different design concepts meant to address the same requirements. NASA’s Artemis program includes the development of a base camp near the lunar South Pole. After site selection is made, one of the first infrastructure elements needed will be a launch and landing pad (LLP). The construction of such a pad will prevent damage to nearby structures from plume-surface interaction (PSI) while also providing a stable platform for the lander. These benefits reduce the required distance between the established landing zones and other settlement infrastructure. In this paper, the authors evaluate the requirements associated with lunar LLP development, application of both functional and topological optimization techniques, methodologies to combine the two techniques, and potential impacts on final design of such a pad.

In-situ↗

NASA NTRS1998

Development of Lead Free Energy Absorber for Space Shuttle Blast Container

The Space Shuttle vehicle (SSV) is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers (BC) are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the SSV and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the BC for two specific reasons; 1. to eliminate lead for environmental concerns, and 2. to reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hangups. This upgrade will replace the lead liner with an aluminum foam material. The aluminum foam used as a energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: A. Lead handling/ exposure, and possible contamination, along with hazardous waste disposal will be eliminated; B. Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam over lead; C. The new aluminum liner is designed to catch all shrapnel from frangible nuts thus virtually eliminating chance of foreign object debris (FOD) exiting the HDP, and causing potential damage to the vehicle; D. Potential of using the lighter aluminum liner over lead, allows for easier assembly and disassembly of blast container elements, also allowing for improvements in safety, operator handling, and efficiency of operations. Six BC firing tests will be required to determine if the new liner material will perform in a way to decrease the chance of stud hangups and enhance the ability of the BC to retain blast debris. Testing will be performed at the Kennedy Space Center (KSC) facility known as the Launch Equipment Test Facility (LETF), and will simulate the SRB hold- down post, with actual BC hardware and pyrotechnics assembled, and then test fired. Initial testing was performed in 1997 using a frangible nut in a static drop test over lead and aluminum foam sheet materials. The aluminum foam showed a dramatic improvement of energy absorption over the lead liner material. Proof-of-Principle testing at the KSC-LETF commenced in May, 1998, and is expected to be completed by June, 1998.

Ingram, T.↗

NASA NTRSDate not supplied

A Comparison of Microstructure and Mechanical Performance of Inconel 718 Manufactured via L-PBF, LP-DED, and WAAM Technologies

The microstructure and mechanical properties of additively manufactured (AM) alloys can be significantly affected by variations in cooling rates, resulting from different process conditions across different additive manufacturing (AM) platforms. Therefore, it is crucial to understand the effect of manufacturing process on the microstructure and mechanical properties of AM Inconel 718. This study examines three AM processes: laser powder bed fusion, laser powder directed energy deposition, and wire arc additive manufacturing. Results show that fully heat treated laser powder bed fused (L-PBF) and wire arc additively manufactured (WAAM) Inconel 718 specimens exhibit higher strength compared to laser powder directed energy deposited (LP-DED) ones due to finer grain structure in L-PBF and retained dendritic microstructure in WAAM. The ductility in LP-DED Inconel 718 was slightly higher compared to WAAM and L-PBF due to relatively small carbide size, which causes stress concentration in a small material volume, leading to delayed fracture.

Additive manufacturing (AM)↗

NASA NTRS2003

The Fluids Integrated Rack and Light Microscopy Module Integrated Capabilities

The Fluids Integrated Rack (FIR), a facility class payload, and the Light Microscopy Module (LMM), a subrack payload, are scheduled to be launched in 2005. The LMM integrated into the FIR will provide a unique platform for conducting fluids and biological experiments on ISS. The FIR is a modular, multi-user scientific research facility that will fly in the U.S. laboratory module, Destiny, of the International Space Station (ISS). The first payload in the FIR will be the Light Microscopy Module (LMM). The LMM is planned as a remotely controllable, automated, on-orbit microscope subrack facility, allowing flexible scheduling and control of fluids and biology experiments within the FIR. Key diagnostic capabilities for meeting science requirements include video microscopy to observe microscopic phenomena and dynamic interactions, interferometry to make thin film measurements with nanometer resolution, laser tweezers for particle manipulation, confocal microscopy to provide enhanced three-dimensional visualization of structures, and spectrophotometry to measure photonic properties of materials. The LMM also provides experiment sample containment for frangibles and fluids. This paper will provide a description of the current FIR and LMM designs, planned capabilities and key features. In addition a brief description of the initial five experiments planned for LMM/FIR will be provided.

Motil, Susan M.↗

NASA NTRSDate not supplied

GL4U: Training the next generation of bioinformaticians, one omics datatype at a time

Spaceflight modifies gene expression in every organism examined to date, including humans. Understanding how these gene expression changes affect physiology is crucial for the development of countermeasures to enable long-duration manned missions. NASA’s GeneLab project provides researchers open access to multi-omics data, including genetic and gene expression data, from spaceflight experiments that can be mined to understand the effects of spaceflight on biological systems. To ensure new knowledge generation through data re-use, it is important to maximize the number of scientists who utilize GeneLab data. Training students on the GeneLab platform is the best way to create long-term adopters of this NASA database and its tools. Turning students into future instructors and advocates will also accelerate the dissemination of these data and tools to the broader scientific community. Therefore, in collaboration with the GeneLab Educational Working Group (EWG), GeneLab has created GeneLab for Colleges and Universities (GL4U). GL4U provides space biology-relevant training in bioinformatics to the next generation of scientists through direct and indirect approaches. The GeneLab team plans to host two annual data processing bootcamps, one for college-level students (direct) and one for college educators (indirect – training of trainers), in which participants learn to analyze GeneLab’s space-relevant omics data. During the bootcamp, educators will receive materials and training to enable them to run the bootcamp at their home institutions or alternatively to adapt the content to implement within existing courses, thereby extending the reach of this initiative. The GL4U direct training pilot program was conducted in June 2021 in collaboration with USRA and San Jose State University (SJSU). During the pilot, SJSU students participated in a week-long bootcamp consisting of space biology-specific lectures and hands-on instruction using Jupyter Notebooks to analyze RNA sequence data. This pilot demonstrates the capacity of GL4U for training young scientists and encouraging data re-use.

Jonathan Matthew Galazka↗

NASA NTRSDate not supplied

Inflatable Softgoods Testing Capability Development for Habitation

The Habitation Systems Development Office (HP40) at NASA Marshall Space Flight Center supports systems engineering, integration, and project management for next generation space habitats. The office is responsible for formulation activities for Lunar Surface Habitat and Mars Transit Habitat. HP40 also manages commercial partnerships for exploration habitat development. The Lunar Surface Habitat is intended to initially support a minimum of two crew on the lunar surface for an approximately 30-day mission, with the ability to accommodate four crew for short durations. The Mars Transit Habitat will transport four crew to and from Mars orbit on a potentially 1,200 day mission. Both concepts are envisioned to leverage inflatable softgoods as the primary structural material for the habitation portion of the architecture. Inflatable softgoods are a complex, multi-material system consisting of multiple layers which perform specific functions. A bladder layer (polymer) contains the habitat’s atmosphere. The bladder is indexed to a woven restraint layer, usually Kevlar or Vectran, which serves as the structural layer. The remaining outer layers are for micro-meteoroid orbital debris (MMOD) shielding, protection from atomic Oxygen (if the material system is to be deployed in low earth orbit), and thermal insulation. The primary advantage of inflatable softgoods is that they can offer a larger volume per unit mass relative to a rigid metal structure. Inflatable softgoods have a strong development heritage within NASA, beginning with work in the 1960s in partnership with Goodyear Aerospace and continuing with Johnson Space Center’s TransHab project in the 1990s . Some development efforts subsequently transitioned into the private sector to mature the material technology for flight applications, including human habitation. In August 2022, NASA published its guidelines for certification of crewed inflatable softgoods structures (JSC-67721). This document outlines a series of tests which will be needed to certify inflatable softgoods material systems for use in crewed mission applications. It includes burst testing at the subscale and full-scale to determine the ultimate burst pressure of the softgoods architecture. Creep (long term deformation of the material under stress) is a key failure mode which must be characterized. Creep testing at the component and module levels is also recommended to generate time to failure curves and verify that the inflatable system has a predicted operational life which exceeds mission parameters. ET (Test Engineering) at MSFC and HP40 have worked together to establish softgoods testing capabilities for the center. This includes the ability to conduct module level burst tests and creep tests. The poster will highlight these capabilities and provide examples of testing which has been performed to date by ET. NASA MSFC anticipates that these test capabilities will continue to offer critical support for companies pursuing inflatable softgoods for exploration applications (lunar surface habitation, Mars transit) as well as commercial low earth orbit platforms.

habitation↗

NASA NTRS2012

External Contamination Control of Attached Payloads on the International Space Station

The International Space Station (ISS) is an on-orbit platform for science utilization in low Earth orbit with multiple sites for external payloads with exposure to the natural and induced environments. Contamination is one of the induced environments that can impact performance, mission success and science utilization on the vehicle. This paper describes the external contamination control requirements and integration process for externally mounted payloads on the ISS. The external contamination control requirements are summarized and a description of the integration and verification process is detailed to guide payload developers in the certification process of attached payloads on the vehicle. A description of the required data certification deliverables covers the characterization of contamination sources. Such characterization includes identification, usage and operational data for each class of contamination source. Classes of external contamination sources covered are vacuum exposed materials, sources of leakage, vacuum venting and thrusters. ISS system level analyses are conducted by the ISS Space Environments Team to certify compliance with external contamination control requirements. This paper also addresses the ISS induced contamination environment at attached payload sites, both at the requirements level as well as measurements made on ISS.

Soares, Carlos E.↗

NASA NTRS2020

Elastic wave analyzer for icy sub-surfaces (EWAIS) in the solar system

The sub-surface structures of water-bearing icy worlds (e.g., Europa, Enceladus, and Titan) and the structures of icy regions on Mars contain critical information about their origin and evolution. These bodies have been identified as high-priority targets in the NRC Planetary Science Decadal Survey, which noted a lack of technology readiness as one impediment to related missions. An Elastic Wave Analyzer for Icy Sub-surfaces (EWAIS) instrument is being developed to acquire data that can provide answers to fundamental science questions related to these bodies. The EWAIS instrument generates and receives elastic waves using an array of piezoelectric transducers capable of operating at temperatures as low as 30K. A developed breadboard acquires reflected signals from discontinuities in the traveled materials’ impedance (the product of wave velocity and density) along the wave path. Analysis of the acquired data can be used to determine the elastic properties, presence of cracks, locations of cavities and other discontinuities, as well as the thicknesses of ice and liquid layers. The EWAIS instrument is being developed with a novel dual-frequency transmitter array that will enable reaching distances of kilometers through ice, as well as resolving smaller acoustic reflectors nearer the EWAIS instrument. The selected dual frequencies correspond to two depth ranges that can be analyzed, with resolutions of tens of centimeters in the region of tens to hundreds of meters and tens of meters on the kilometers scale, respectively. The EWAIS will be applicable for operation from any in-situ platform, including surface assets (e.g., lander and rover) and sub-surface assets (e.g., melting probes).

Bar-Cohen, Y.↗

NASA NTRS1998

Development of Lead Free Energy Absorber for Space Shuttle Blast Container

The Space Shuttle is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the Space Shuttle and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the blast container for two specific reasons: (1) To eliminate lead for environmental concerns, and (2) To reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hang-ups. This upgrade will replace the lead liner with a unique open cell aluminum foam material, that has commercial and military uses. The aluminum foam used as an energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: (A) Lead handling/exposure and possible contamination, along with hazardous waste disposal, will be eliminated; (B) Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam instead of lead; (C) The new aluminum liner is designed to catch all shrapnel from frangible nuts, thus virtually eliminating chance of debris exiting the HDP and causing potential damage to the vehicle; and (D) Using the lighter aluminum liner instead of lead, allows for easier assembly and disassembly of blast container elements, which also improves safety, operator handling, and the efficiency of operations.

Balles, Donald↗

NASA NTRS1999

Development of Lead Free Energy Absorber for Space Shuttle Blast Container

The Space Shuttle is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the Space Shuttle and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the blast container for two specific reasons: (1) To eliminate lead for environmental concerns, and (2) To reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hang-ups. This upgrade will replace the lead liner with a unique open cell aluminum foam material, that has commercial and military uses. The aluminum foam used as an energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: (1) Lead handling / exposure and possible contamination, along with hazardous waste disposal, will be eliminated; (2) Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam instead of lead; (3) The new aluminum liner is designed to catch all shrapnel from frangible nuts, thus virtually eliminating chance of debris exiting the HDP and causing potential damage to the vehicle; (4) Using the lighter aluminum liner instead of lead, allows for easier assembly and disassembly of blast container elements, which also improves safety, operator handling, and the efficiency of operations.

Balles, Donald↗

NASA NTRSDate not supplied

Ruggedizing a Commercial Depth Camera for Novel Lunar Exploration.

The novel contribution of this instrument is to take the first depth images on the moon. A commercial Kinect camera from Microsoft has been ruggedized for a CLPS mission to the Lunar South Pole. The 12-megapixel color camera is combined with a 1-megapixel color time-of-flight (ToF) depth sensor. The solid-state depth sensor/LIDAR provides greater resolution, a wider field of view, pixel binning, and reduced power consumption. The high-resolution data collected from the mission can be used to construct a near-field virtual environment of the lunar surface for scientific applications. The depth camera can provide a 360-degree view of the target area by combining ToF data with RGB imagery and rover turning. The unit was evaluated for space flight compliant materials and parts at NASA Ames. The microphone array, RF shield, front face, and outer body parts were removed to reduce mass. Plastic parts were replaced with vacuum-compatible materials; manufactured cables were added to properly interface with the host rover, built by Lunar Outpost. The environmental testing was performed on the Kinect with Random Vibration/Sine Testing (Fig 1a), per GEVS (NASA’s General Environmental Verification Standard for spaceflight launch survival). Thermal Vacuum testing cycled the instrument between expected hot (+ 85 C) and cold survival temperatures, as well as +50 C and -25 C operational temps (Fig 1b). The instrument functioned nominally at the conclusion of vibration and thermal cycling tests. The Azure Kinect is manifested on the Nova-C lander which flies on the Intuitive Machines mission IM-2, landing at the lunar south pole for a mission duration of 14 days (one lunar daylight cycle). The unit will be integrated to the MAPP (Mobile Autonomous Prospecting Platform) rover at Lunar Outpost. The Azure Kinect with ToF feature will improve the resolution of lunar geology data near the south pole and enable ground-based VR experience of details of the lunar surface (Fig 1c).

V. Jha↗

NASA NTRS1987

Systems autonomy technology: Executive summary and program plan

The National Space Strategy approved by the President and Congress in 1984 sets for NASA a major goal of conducting effective and productive space applications and technology programs which contribute materially toward United States leadership and security. To contribute to this goal, OAST supports the Nation's civil and defense space programs and overall economic growth. OAST objectives are to ensure timely provision of new concepts and advanced technologies, to support both the development of NASA missions in space and the space activities of industry and other organizations, to utilize the strengths of universities in conducting the NASA space research and technology program, and to maintain the NASA centers in positions of strength in critical space technology areas. In line with these objectives, NASA has established a new program in space automation and robotics that will result in the development and transfer and automation technology to increase the capabilities, productivity, and safety of NASA space programs including the Space Station, automated space platforms, lunar bases, Mars missions, and other deep space ventures. The NASA/OAST Automation and Robotics program is divided into two parts. Ames Research Center has the lead role in developing and demonstrating System Autonomy capabilities for space systems that need to make their own decisions and do their own planning. The Jet Propulsion Laboratory has the lead role for Telerobotics (that portion of the program that has a strong human operator component in the control loop and some remote handling requirement in space). This program is intended to be a working document for NASA Headquarters, Program Offices, and implementing Project Management.

Bull, John S↗

NASA NTRS2020

A Review of Welding in Space and Related Technologies

Deployment of welding and additive manufacturing (AM) technologies in the space environment has the potential to revolutionize how orbiting platforms are designed, manufactured, and assembled. These technologies offer the option for repair of sustained damage to habitat structures on space missions, as astronauts would be able to manufacture new parts (using welding-derived AM processes suitable for use in the external space environment) and weld cracks. An added benefit is that required repairs can be achieved more economically, as new parts need not be shipped from Earth. With further maturation of in-space welding capabilities, astronauts could operate under given standards and weld damaged structures rather than rely on cargo resupply. This Technical Memorandum (TM) begins by reviewing the available literature relevant to welding in space, focusing on solidification, heat and mass transfer, and fluid flows in microgravity. This survey considers research on the effects of welding in microgravity on a material system. The various in-space welding devices that have been previously designed and tested are examined to determine their capabilities and shortcomings, with a focus on the results of their individual welding experiments. Safety measures are discussed to protect the orbiting International Space Station (ISS) and crew during welding operations. Finally, the state of the art is examined by focusing on current approaches to AM and on-orbit welding that are being developed by several companies in conjunction with NASA.

Naden, N.↗