Early Stage Innovations (ESI) 2024

Early Stage Innovations (ESI) 2024

1 min read

Preparations for Next Moonwalk Simulations Underway (and Underwater)

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Computational Materials Engineering for Lunar Metals Welding

Passive Lunar Dust Control through Advanced Materials and Surface Engineering

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Loura Hall

Weld-ASSIST: Weldability Assessment for In-Space Conditions using a Digital Twin

Weld-ASSIST: Weldability Assessment for In-Space Conditions using a Digital Twin

2 min read

Preparations for Next Moonwalk Simulations Underway (and Underwater)

ESI24 Haghighi Quadchart

Azadeh Haghighi
University of Illinois, Chicago

In-space manufacturing and assembly are vital to NASA’s long-term exploration goals, especially for the Moon and Mars missions. Deploying welding technology in space enables the assembly and repair of structures, reducing logistical burdens and supply needs from Earth. The unique challenges and extreme conditions of space–high thermal variations, microgravity, and vacuum–require advanced welding techniques and computational tools to ensure reliability, repeatability, safety, and structural integrity in one-shot weld scenarios. For the first time, this project investigates these challenges by focusing on three key factors: (1) Very low temperatures in space degrade the weldability of high thermal conductivity materials, like aluminum alloys, making it harder to achieve strong, defect-free welds. (2) The extreme vacuum in space lowers the boiling points of alloying elements, altering the keyhole geometry during welding. This selective vaporization changes the weld’s final chemical composition, affecting its microstructure and properties. (3) Microgravity nearly eliminates buoyancy-driven flow of liquid metal inside the molten pool, preventing gas bubbles from escaping, which leads to porosity and defects in the welds. By examining these critical factors using multi-scale multi-physics models integrated with physics-informed machine learning, and forward/inverse uncertainty quantification techniques, this project provides the first-ever real-time digital twin platform to evaluate welding processes under extreme space/lunar conditions. The models are validated through Earth-based experiments, parabolic flight tests, and publicly available data from different databases and agencies worldwide. Moreover, the established models will facilitate extendibility to support in-situ resource utilization on the Moon, including construction and repair using locally sourced materials like regolith. The established fundamental scientific knowledge will minimize trial-and-error, enable high-quality one-shot welds in space, and reduce the need for reworks, significantly reducing the costs and time needed for space missions.

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Loura Hall

Integrated Computational Materials Modelling Framework for Investigating the Process-Structure-Property Linkage of the Lunar Metal Welding with Internal Defects

Integrated Computational Materials Modelling Framework for Investigating the Process-Structure-Property Linkage of the Lunar Metal Welding with Internal Defects

1 min read

Preparations for Next Moonwalk Simulations Underway (and Underwater)

ESI24 Li Quadchart

Wei Li
University of Texas at Dallas

Internal defects are always formed in laser welding process due to the keyhole instability, molten pool collapse, and rapid solidification. The extreme lunar environment complicates the reliable implementation of welding, thereby enhancing the welding defects formation. The welding defects are critical material barriers preventing the metal components from Moon exploration. Professor Wei Li’s team will establish an integrated computational materials modelling framework to study the process-structure-property linkage of laser welding under the lunar conditions. The research is emphasized on modelling the internal defects (void, lack of fusion) formed in the lunar laser welding by fully considering the reduced gravity, large temperature change, and extreme vacuum on the Moon surface, and predicting the influence of internal defects on the material and mechanical properties of welding joint.

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Loura Hall

Deformable Crumpled Nano-ball Coatings with Adaptable Adhesion and Mechanical Energy Absorption for Lunar Dust Mitigation

Deformable Crumpled Nano-ball Coatings with Adaptable Adhesion and Mechanical Energy Absorption for Lunar Dust Mitigation

2 min read

Preparations for Next Moonwalk Simulations Underway (and Underwater)

ESI24 Nam Quadchart

SungWoo Nam
University of California, Irvine

Lunar dust may seem unimposing, but it presents a significant challenge for space missions. Its abrasive and jagged particles can damage equipment, clog devices, and even pose health risks to astronauts. This project addresses such issues by developing advanced coatings composed of crumpled nano-balls made from atomically thin 2D materials such as MoS₂, graphene, and MXenes. By crumpling these nanosheets—much like crumpling a piece of paper—we create compression and aggregation resistant particles that can be dispersed in sprayable solutions. As a thin film coating, these crumpled nano-balls form corrugated structures that passively reduce dust adhesion and surface wear. The deformable crumpled nano-ball (DCN) coating works by minimizing the contact area between lunar dust and surfaces, thanks to its unique nano-engineered design. The 2D materials exhibit exceptional durability, withstanding extreme thermal and vacuum environments, as well as resisting radiation damage. Additionally, the flexoelectric and electrostatically dissipative properties of MoS₂, graphene, and MXenes allow the coating to neutralize and dissipate electrical charges, making them highly responsive to the charged lunar dust environment. The project will be executed in three phases, each designed to bring the technology closer to real-world space applications. First, we will synthesize the crumpled nano-balls and investigate their adhesion properties using advanced microscopy techniques. The second phase will focus on fundamental testing in simulated lunar environments, where the coating will be exposed to extreme temperatures, vacuum, radiation, and abrasion. Finally, the third phase will involve applying the coating to space-heritage materials and conducting comprehensive testing in a simulated lunar environment, targeting up to 90% dust clearance and verifying durability over repeated cycles of dust exposure. This research aligns with NASA’s goals for safer, more sustainable lunar missions by reducing maintenance requirements and extending equipment lifespan. Moreover, the potential applications extend beyond space exploration, with the technology offering promising advances in terrestrial industries such as aerospace and electronics by providing ultra-durable, wear-resistant surfaces. Ultimately, the project contributes to advancing materials science and paving the way for NASA’s long-term vision of sustainable space exploration.

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Loura Hall

Engineering the Adhesion Mechanisms of Hierarchical Dust-Mitigating Nanostructures

Engineering the Adhesion Mechanisms of Hierarchical Dust-Mitigating Nanostructures

1 min read

Preparations for Next Moonwalk Simulations Underway (and Underwater)

ESI24 Chang Quadchart

Chih-Hao Chang
University of Texas at Austin

Establishing a permanent base on the moon is a critical step in the exploration of deep space. One significant challenge observed during the Apollo missions was the adhesion of lunar dust, which can build up on vehicle, equipment, and space suit. Highly fine and abrasive, the dust particles can have adverse mechanical, electrical, and health effects. The proposed research aims to develop a new class of hierarchical, heterogenous nanostructured coating that can passively mitigate adhesion of lunar particles. Using scalable nanolithography and surface modification processes, the geometry and material composition of the nanostructured surface will be precisely engineered to mitigate dust adhesion. This goal will be accomplished by: (1) construct multi-physical models to predict the contributions of various particle adhesion mechanisms, (2) develop scalable nanofabrication processes to enable precise control of hierarchical structures, and (3) develop nanoscale single-probe characterization protocols to characterize adhesion forces in relevant space environments. The proposed approach is compatible with roll-to-roll processing and the dust-mitigation coating can be transfer printed on arbitrary metal, ceramic, and polymer surfaces such as space suits, windows, mechanical machinery, solar panels, and sensor systems that are vital for long-term space exploration.

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Loura Hall