In groundbreaking experiments, NASA, Air Force Research Laboratory (AFRL), and Ohio State University are pushing the boundaries of technology by reinstating welding in space. This initiative is particularly exciting as it opens new possibilities for manufacturing and repairs beyond our planet. To prepare for this complex task, the teams conducted preliminary tests on laser welding in a vacuum chamber, employing an innovative approach to simulate zero-gravity conditions. This was achieved using a special aircraft capable of performing parabolic flights, where the researchers experience weightlessness for 20-25 seconds at a time.
The tests are crucial for understanding how welding processes behave in the unique environment of space, where factors such as gravity, temperature, and pressure differ significantly from those on Earth. To effectively monitor these welding experiments, two advanced Xiris cameras—a monitoring camera and a thermal camera—were placed inside the vacuum chamber. Despite the harsh conditions of vacuum and zero-gravity, these cameras performed exceptionally well, providing invaluable data for the research teams. Being the company specializing in the design and manufacture of these cameras, we take great pride in their performance during this pivotal study.
The Importance of Welding in Space
Welding in space is not just a technical challenge; it is a necessity for the future of space exploration. As we embark on long-term crewed missions beyond Earth and explore the possibility of settlements on the Moon and Mars, the significance of space welding continues to grow. Space welding will enable the direct assembly of large structures like space stations and lunar habitats in orbit, avoiding the costs and limitations associated with transporting prefabricated components from Earth. Moreover, the ability to weld in space is essential for repairing damaged spacecraft; even minor issues can jeopardize missions or render expensive satellites inoperable. In more distant future, welding techniques that utilize locally sourced lunar or Martian materials could also facilitate on-site production of tools and structures, reducing reliance on Earth-based supplies. In the perilous environment of space, the ability to weld damaged components can be lifesaving during emergencies, highlighting its critical role in ensuring crew safety.
However, welding in space presents unique challenges for scientists and engineers, including the vacuum environment, microgravity, temperature fluctuations, and radiation exposure. Overcoming these obstacles is crucial for the construction and repair of structures in space, making expertise in space welding essential for future exploration. Traditional methods of manufacturing and repairs on Earth may not be viable in the space environment. Thus, understanding how welding techniques can be adapted for zero-gravity conditions is critical. To address these challenges, a group of researchers and students from NASA and Ohio State University designed and conducted a unique set of experiments.
The Experiment
The experimental setup included a large vacuum chamber paired with a laser beam system. The laser head was positioned above the chamber, allowing the laser beam to pass through a special window, while Xiris cameras were installed inside the vacuum chamber, directly facing the weld area (Figure 1).
Both the vacuum chamber and laser system were housed in a modified airplane. This aircraft executed sections of flight along a parabolic trajectory, during which gravitational force inside the cabin dropped to zero, creating a weightless environment for the researchers and equipment for 20-25 seconds. The welding tests were conducted during these brief periods of microgravity, effectively simulating space conditions without leaving Earth.
The Role of Xiris Cameras in Space Welding Tests
Aaron Brimmer, a PhD student in Welding Engineering from Ohio State University, who was directly involved in the welding experiments, shed light on the reasons behind the necessity of specialized weld cameras for this research. He stated:
“Our work in researching laser welding for space conditions required us to operate experiments in zero gravity—accomplished on the ground by parabolic flight campaigns. These campaigns are extremely expensive and difficult to run, so high-speed weld and thermal videography allowed us to maximize the amount of data collected per parabola.
"We chose Xiris thermal and weld cameras for two primary reasons: high reliability and the ability to operate within a vacuum. Reliability was key for our work; every second that we had during our zero gravity was precious. The cameras worked without a hitch, and Xiris’ cooperation allowed us to build a robust system for capturing video during parabolic flight work, operating almost autonomously from LabVIEW.
The other reason why these cameras were chosen was our necessity to operate fully within a high-vacuum environment. Understandably, commercial off-the-shelf options for weld videography within a vacuum are hard or impossible to come by. With some careful design on our part and Xiris’ help, we were able to successfully use two Xiris cameras within a high vacuum while maintaining a 100% duty cycle on one camera and 60-80% duty cycle on a second.”
Looking to the Future
As the researchers continue their pioneering work in welding for space applications, the insights gained from these initial tests will pave the way for future advancements in aerospace manufacturing. The ability to weld in space not only enhances our capabilities for exploration but also lays the groundwork for sustainable living on other planets.
As we look ahead, the collaboration between Xiris Automation, NASA, and Ohio State University represents a significant step forward in space welding technology. We are proud of the role our cameras played in these groundbreaking experiments, providing critical data in the challenging environments of vacuum and zero gravity. This partnership has strengthened our commitment to supporting innovative research.
With more projects on the horizon, we are excited to continue this journey together. The future of space exploration relies on our ability to adapt and evolve technologies for unprecedented challenges, and we are eager to contribute to the advancements that will shape humanity's next chapter beyond Earth.
This project is made possible through financial support from NASA’s Marshall Space Flight Center (MSFC), AFRL Midwest Hub, and the Ohio Federal Research Network (OFRN).
References
[1]. Choi, E., A. Brimmer, W. McAuley, B. Panton, A. Ramirez, W. Evans, A. O'Connor, Z. Courtright, and J. W. Sowards. "Laser Beam Welding for in-Space Joining Demonstrated Under Vacuum on the Ground and By Parabolic Flight Experiments." In DoD NDEP STEM. 2024.
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