Laser Beam Welding of Structural Materials in Space

As countries and private companies around the world have engaged in a new space race, not only to explore but also to utilize space and colonize other cosmic bodies, such as the Moon and Mars, manufacturing in space is no longer a distant dream but a pressing need. Therefore, materials joining in space has become a critical enabling technology for the rapidly growing in-space servicing, assembly, and manufacturing (ISAM) sector. Today, no metallurgical joining processes have been proven fit-for-service for execution in space. There is limited fundamental understanding of the effects of the space environment (gravity, atmosphere, and temperature) on the joining processes, the metallurgy, and performance of the joints. The current inability to effectively join materials in space significantly impairs the advancement of space exploration and the economy. Our team, which also includes several members from NASA MSFC, LRC, and GRC, investigates the impact of space conditions on Laser Beam Welding (LBW) of metallic alloys. A 1 kW, 1070nm Yb-fiber pulsed laser was fitted into a vacuum chamber for microgravity experiments. To mimic space, our experimental setup rides aboard a parabolic flight where high-vacuum and variable gravity (from µg to 1.8g) experiments address the impact on weld geometry, microstructure, and defect formation on AA-2219, 316L stainless steel, and Ti-based alloys. This research represents a significant step toward qualifying LBW for ISAM applications, supporting the broader goal of enabling autonomous, on-demand fabrication and repair in orbit and beyond. Ultimately, the insights gained from this work contribute to the development of robust and predictive Integrated Computational Materials Engineering (ICME) frameworks, helping to establish design and process qualification standards for welding in space.