NASA to Transform In-Space Manufacturing with Laser Beam Welding Collaboration

By Wayne Smith

As NASA plans for humans to return to the Moon and eventually explore Mars, a laser beam welding collaboration between NASA’s Marshall Space Flight Center in Huntsville, Alabama, and The Ohio State University in Columbus aims to stimulate in-space manufacturing.

The multi-year effort seeks to understand the physical processes of welding on the lunar surface, such as investigating the effects of laser beam welding in a combined vacuum and reduced gravity environment. The goal is to increase the capabilities of manufacturing in space to potentially assemble large structures or make repairs on the Moon, which will inform humanity’s next giant leap of sending astronauts to Mars and beyond.

“For a long time, we’ve used fasteners, rivets, or other mechanical means to keep structures that we assemble together in space,” said Andrew O’Connor, a Marshall materials scientist who is helping coordinate the collaborative effort and is NASA’s technical lead for the project. “But we’re starting to realize that if we really want strong joints and if we want structures to stay together when assembled on the lunar surface, we may need in-space welding.” The ability to weld structures in space would also eliminate the need to transport rivets and other materials, reducing payloads for space travel. That means learning how welds will perform in space.

To turn the effort into reality, researchers are gathering data on welding under simulated space conditions, such as temperature and heat transfer in a vacuum; the size and shape of the molten area under a laser beam; how the weld cross-section looks after it solidifies; and how mechanical properties change for welds performed in environmental conditions mimicking the lunar surface.

“Once you leave Earth, it becomes more difficult to test how the weld performs, so we are leveraging both experiments and computer modeling to predict welding in space while we’re still on the ground,” said O’Connor.

In August 2024, a joint team from Ohio State’s Welding Engineering and Multidisciplinary Capstone Programs and Marshall’s Materials & Processes Laboratory performed high-powered fiber laser beam welding aboard a commercial aircraft that simulated reduced gravity. The aircraft performed parabolic flight maneuvers that began in level flight, pulled up to add 8,000 feet in altitude, and pushed over at the top of a parabolic arc, resulting in approximately 20 seconds of reduced gravity to the passengers and experiments.

While floating in this weightless environment, team members performed laser welding experiments in a simulated environment similar to that of both low Earth orbit and lunar gravity. Analysis of data collected by a network of sensors during the tests will help researchers understand the effects of space environments on the welding process and welded material.

“During the flights we successfully completed 69 out of 70 welds in microgravity and lunar gravity conditions, realizing a fully successful flight campaign,” said Will McAuley, an Ohio State welding engineering student.

Funded in part by Marshall and spanning more than two years, the work involves undergraduate and graduate students and professors from Ohio State, and engineers across several NASA centers. Marshall personnel trained alongside the university team, learning how to operate the flight hardware and sharing valuable lessons from previous parabolic flight experiments. NASA’s Langley Research Center in Hampton, Virginia, developed a portable vacuum chamber to support testing efforts.

The last time NASA performed welding in space was during the Skylab mission in 1973. Other parabolic tests have since been performed, using low-powered lasers. Practical welding and joining methods and allied processes, including additive manufacturing, will be required to develop the in-space economy. These processes will repurpose and repair critical space infrastructure and could build structures too large to fit current launch payload volumes. In-space welding could expedite building large habitats in low Earth orbit, spacecraft structures that keep astronauts safe on future missions, and more.

The work is also relevant to understanding how laser beam welding occurs on Earth. Industries could use data to inform welding processes, which are critical to a host of manufactured goods from cars and refrigerators to skyscrapers.

“We’re really excited about laser beam welding because it gives us the flexibility to operate in different environments,” O’Connor said.

There has been a resurgence of interest in welding as we look for innovative ways to put larger structures on the surface of the Moon and other planets.

Andrew O’Connor

Marshall Space Flight Center materials scientist

This effort is sponsored by NASA Marshall’s Research and Development funds, the agency’s Science Mission Directorate Biological and Physical Sciences Division of the agency’s Science Mission Directorate, and NASA’s Space Technology Mission Directorate, including NASA Flight Opportunities.

For more information about NASA’s Marshall Space Flight Center, visit:

https://www.nasa.gov/marshall

Joel Wallace
Marshall Space Flight Center, Huntsville, Alabama
256.544.0034
joel.w.wallace@nasa.gov

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Student-Built Capsules Endure Heat of Re-entry for NASA Science

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Student-Built Capsules Endure Heat of Re-entry for NASA Science

In July 2024, five student-built capsules endured the scorching heat of re-entry through Earth’s atmosphere as part of the second Kentucky Re-Entry Probe Experiment (KREPE-2). Scientists are now analyzing the data from the KREPE-2 experiments, which could advance the development of heat shields that protect spacecraft when they return to Earth.

The mission was designed to put a variety of heat shield prototypes to the test in authentic re-entry conditions to see how they would perform. These experimental capsules, which were built by students at the University of Kentucky and funded by the NASA Established Program to Stimulate Competitive Research (EPSCoR) within NASA’s Office of STEM Engagement, all survived more than 4,000 degrees Fahrenheit during descent.

The football-sized capsules also successfully transmitted valuable data via the Iridium satellite network along their fiery journey. The trove of information they provided is currently being analyzed to consider in current and future spacecraft design, and to improve upon designs for future experiments.

“These data – and the instruments used to obtain the data – assist NASA with designing and assessing the performance of current and new spacecraft that transport crew and cargo to and from space,” said Stan Bouslog, thermal protection system senior discipline expert at NASA’s Johnson Space Center in Houston who served as the agency’s technical monitor for the project.

Taking the Plunge: Communicating Through a Fiery Descent

“The only way to ‘test like you fly’ a thermal protection system is to expose it to actual hypersonic flight through an atmosphere,” Bouslog said.

The self-contained capsules launched aboard an uncrewed Northrop Grumman Cygnus spacecraft in January 2024 along with other cargo bound for the International Space Station. The cargo craft detached from the space station July 12 as the orbiting laboratory flew above the south Atlantic Ocean. As the Cygnus spacecraft began its planned breakup during re-entry, the KREPE-2 capsules detected a signal – a temperature spike or acceleration – to start recording data and were released from the vehicle. At that point, they were traveling at a velocity of about 16,000 miles per hour at an altitude of approximately 180,000 feet.

The University of Kentucky student team and advisors watched and waited to learn how the capsules had fared.

As the capsules descended through the atmosphere, one group watched from aboard an aircraft flying near the Cook Islands in the south Pacific Ocean, where they tracked the return of the Cygnus spacecraft. The flight was arranged in partnership with the University of Southern Queensland in Toowoomba, Queensland, Australia, and the University of Stuttgart in Stuttgart, Germany. Alexandre Martin, professor of mechanical and aerospace engineering at the University of Kentucky and the principal investigator for the experiment, was on that flight.

“We flew in close to the re-entry path to take scientific measurements,” Martin said, adding that they used multiple cameras and spectrometers to observe re-entry. “We now have a much better understanding of the break-up event of the Cygnus vehicle, and thus the release of the capsules.”

Meanwhile, members of the University of Kentucky’s Hypersonic Institute had gathered at the university to watch as KREPE-2 data arrived via email. All five successfully communicated their flight conditions as they hurtled to Earth.

“It will take time to extract the data and analyze it,” Martin said. “But the big accomplishment was that every capsule sent data.”

Members of the University of Kentucky student team have begun analyzing the data to digitally reconstruct the flight environment at the time of transmission, providing key insights for future computer modeling and heat shield design.

Building on Student Success

The mission builds on the accomplishments of KREPE-1, which took place in December 2022. In that experiment, two capsules recorded temperature measurements as they re-entered Earth’s atmosphere and relayed that data to the ground.

The extensive dataset collected during the KREPE-2 re-entry includes heat shield measurements, such as temperature, as well as flight data including pressure, acceleration, and angular velocity. The team also successfully tested a spectrometer that provided spectral data of the shockwave in front of a capsule.

“KREPE-1 was really to show we could do it,” Martin said. “For KREPE-2, we wanted to fully instrument the capsules and really see what we could learn.”

KREPE-3 is currently set to take place in 2026.

The ongoing project has provided valuable opportunities for the University of Kentucky student team, from undergrads to PhD students, to contribute to spaceflight technology innovation.

“This effort is done by students entirely: fabrication, running simulations, handling all the NASA reviews, and doing all the testing,” Martin said. “We’re there supervising, of course, but it’s always the students who make these missions possible.”

Related links:

• EPSCoR
• Space Station Research Explorer: Kentucky Re-entry Probe Experiment-2
• Science Launches to Space Station on NASA’s 20th Northrop Grumman Mission
• Big Goals, Small Package: Enabling Compact Deliveries from Space

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NASA-Funded Study Examines Tidal Effects on Planet and Moon Interiors

NASA-supported scientists have developed a new method to compute how tides affect the interiors of planets and moons. Importantly, the new study looks at the effects of body tides on objects that don’t have a perfectly spherical interior structure, which is an assumption of most previous models.

Body tides refer to the deformations experienced by celestial bodies when they gravitationally interact with other objects. Think of how the powerful gravity of Jupiter tugs on its moon Europa. Because Europa’s orbit isn’t circular, the crushing squeeze of Jupiter’s gravity on the moon varies as it travels along its orbit.  When Europa is at its closest to Jupiter, the planet’s gravity is felt the most. The energy of this deformation is what heats up Europa’s interior, allowing an ocean of liquid water to exist beneath the moon’s icy surface.

“The same is true for Saturn’s moon Enceladus.” says co-author Alexander Berne of CalTech in Pasadena and an affiliate at NASA’s Jet Propulsion Laboratory in Southern California. “Enceladus has an ice shell that is expected to be much more non-spherically symmetric than that of Europa.”

The body tides experienced by celestial bodies can affect how the worlds evolve over time and, in cases like Europa and Enceladus, their potential habitability for life as we know it. The new study provides a means to more accurately estimate how tidal forces affect planetary interiors.

The paper also discusses how the results of the study could help scientists interpret observations made by missions to a variety of different worlds, ranging from Mercury to the Moon to the outer planets of our solar system.

The study, “A Spectral Method to Compute the Tides of Laterally Heterogeneous Bodies,” was published in The Planetary Science Journal. 

For more information on NASA’s Astrobiology Program, visit:

https://science.nasa.gov/astrobiology

-end-

Karen Fox / Molly Wasser

Headquarters, Washington

202-358-1600

karen.c.fox@nasa.gov / molly.l.wasser@nasa.gov 

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Attention Students: NASA Launches Power Systems Student Essay Contest

NASA’s fourth annual Power to Explore Student Challenge kicked off November 7, 2024. The science, engineering, technology, and mathematics (STEM) writing challenge invites kindergarten through 12th grade students in the United States to learn about radioisotope power systems, a type of nuclear battery integral to many of NASA’s far-reaching space missions.

Students are invited to write an essay about a new nuclear-powered mission to any moon in the solar system they choose. Submissions are due Jan. 31, 2025.

With freezing temperatures, long nights, and deep craters that never see sunlight on many of these moons, including our own, missions to them could use a special kind of power: radioisotope power systems. These power systems have helped NASA explore the harshest, darkest, and dustiest parts of our solar system and enabled spacecraft to study its many moons.

“Sending spacecraft into space is hard, and it’s even harder sending them to the extreme environments surrounding the diverse moons in our solar system,” said Nicola Fox, associate administrator, Science Mission Directorate at NASA Headquarters in Washington. “NASA’s Power to Explore Student Challenge provides the incredible opportunity for our next generation – our future explorers – to design their own daring missions using science, technology, engineering, and mathematics to explore space and discover new science for the benefit of all, while also revealing incredible creative power within themselves. We cannot wait to see what the students dream up!”

Entries should detail where students would go, what they would explore, and how they would use radioisotope power systems to achieve mission success in a dusty, dark, or far away moon destination.

Judges will review entries in three grade-level categories: K-4, 5-8, and 9-12. Student entries are limited to 275 words and should address the mission destination, mission goals, and describe one of the student’s unique powers that will help the mission. 

One grand prize winner from each grade category will receive a trip for two to NASA’s Glenn Research Center in Cleveland to learn about the people and technologies that enable NASA missions. Every student who submits an entry will receive a digital certificate and an invitation to a virtual event with NASA experts where they’ll learn about what powers the NASA workforce to dream big and explore.

Judges Needed

NASA and Future Engineers are seeking volunteers to help judge the thousands of contest entries anticipated submitted from around the country. Interested U.S. residents older than 18 can offer to volunteer approximately three hours to review submissions should register to judge at the Future Engineers website.

The Power to Explore Student Challenge is funded by the NASA Science Mission Directorate’s Radioisotope Power Systems Program Office and managed and administered by Future Engineers under the direction of the NASA Tournament Lab, a part of the Prizes, Challenges, and Crowdsourcing Program in NASA’s Space Technology Mission Directorate.

To learn more about the challenge, visit:

https://www.nasa.gov/power-to-explore

-end-

Karen Fox / Molly Wasser
NASA Headquarters, Washington
202-358-1600
karen.c.fox@nasa.gov / molly.l.wasser@nasa.gov

Kristin Jansen
Glenn Research Center, Cleveland
216-296-2203
kristin.m.jansen@nasa.gov

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Lauren E. Low