About this Abstract |
| Meeting |
MS&T25: Materials Science & Technology
|
| Symposium
|
Materials and Manufacturing in Low Earth Orbit (and Beyond)
|
| Presentation Title |
Challenges in Laser Welding for Space: Metal Vapor, Lens Fogging, and Plume Effects |
| Author(s) |
Eugene Choi, Boyd Panton, Antonio Ramirez, Kaue Riffel, Aaron Brimmer, Will McAuley |
| On-Site Speaker (Planned) |
Eugene Choi |
| Abstract Scope |
Laser beam welding (LBW) in space-like vacuum environments presents unique challenges due to uncontrolled metal vapor behavior. During both conduction and keyhole mode LBW, vapor is consistently produced as local temperatures exceed the material’s boiling point. In high vacuum (~10⁻⁵ torr), this vapor expands freely and condenses on surrounding cold surfaces—most critically, the optical window delivering the laser beam. Experiments were conducted using multiple aerospace-relevant alloys. In all cases, progressive lens fogging occurred over repeated welds, degrading beam transmission and weld consistency. Vapor deposition followed line-of-sight paths from the weld, forming reflective coatings on the lens. Interestingly, regions directly heated by the laser remained cleaner, suggesting a thermally driven re-evaporation effect. These results highlight the need for mitigation strategies such as sacrificial optics, heating systems, or shielding. A better understanding of vapor transport in vacuum is essential for reliable LBW systems in future in-space manufacturing. |