| Abstract Scope |
While welding is critical to the fabrication of durable goods on Earth, its application to In-space Servicing, Assembly, and Manufacturing (ISAM) remains largely unproven. As the space industry looks toward on-orbit construction and repair, fundamental studies are needed to mature joining processes for reduced gravity and vacuum conditions. Laser beam welding (LBW) is a promising candidate due to its flexibility, portability, and efficiency. This research expands upon previous flight campaigns and introduces a comprehensive numerical modeling approach using the Finite Element Method (FEM) to simulate in-space welds, calibrated with data collected from parabolic flight experiments.
During parabolic flight experiments in August 2024 and May 2025, aerospace alloys including aluminum, stainless steel, and titanium were welded inside a vacuum chamber modified for microgravity LBW. The system was equipped with thermocouples, along with thermal and weld cameras to capture thermal gradients, melt pool behavior, and spatter dynamics under varying gravitational forces. These data sets provide an opportunity to develop and calibrate FEM models that replicate the unique physics of welding in space-like environments.
This presentation will focus on the development and validation of FEM simulations based on those flight results. The models incorporate vacuum and reduced gravity boundary conditions to capture transient thermal profiles, melt pool morphology, and solidification behavior. Results can help reveal how microgravity alters the performance of welds done in microgravity. By integrating the flight data into numerical models, the work can support a broader vision of Integrated Computational Materials Engineering (ICME) for space applications. The outcomes help bridge experimental and predictive methods, provide a baseline for more detailed fluid flow modeling, and accelerates qualification of LBW as a viable process for future uncrewed space missions and ISAM initiatives. |