A Review of Welding in Space and Related Technologies

Deployment of welding and additive manufacturing (AM) technologies in the space environment has the potential to revolutionize how orbiting platforms are designed, manufactured, and assembled. These technologies offer the option for repair of sustained damage to habitat structures on space missions, as astronauts would be able to manufacture new parts (using welding-derived AM processes suitable for use in the external space environment) and weld cracks. An added benefit is that required repairs can be achieved more economically, as new parts need not be shipped from Earth. With further maturation of in-space welding capabilities, astronauts could operate under given standards and weld damaged structures rather than rely on cargo resupply. This Technical Memorandum (TM) begins by reviewing the available literature relevant to welding in space, focusing on solidification, heat and mass transfer, and fluid flows in microgravity. This survey considers research on the effects of welding in microgravity on a material system. The various in-space welding devices that have been previously designed and tested are examined to determine their capabilities and shortcomings, with a focus on the results of their individual welding experiments. Safety measures are discussed to protect the orbiting International Space Station (ISS) and crew during welding operations. Finally, the state of the art is examined by focusing on current approaches to AM and on-orbit welding that are being developed by several companies in conjunction with NASA

NASA's Centennial Challenge for 3D-Printed Habitat: Phase II Outcomes and Phase III Competition Overview

The 3D-Printed Habitat Challenge is part of NASA's Centennial Challenges Program. NASA's Centennial Challenges seek to accelerate innovation in aerospace technology development through public competitions. The 3D-Printed Habitat Challenge, launched in 2015, is part of the Centennial Challenges portfolio and focuses on habitat design and development of large-scale additive construction systems capable of fabricating structures from in situ materials and/or mission recyclables. The challenge is a partnership between NASA, Caterpillar (primary sponsor), Bechtel, Brick and Mortar Ventures, and Bradley University. Phase I of the challenge was an architectural concept competition in which participants generated conceptual renderings of habitats on Mars which could be constructed using locally available resources. Phase II asked teams to develop the printing systems and material formulations needed to translate these designs into reality. Work under the phase II competition, which concluded in August 2017 with a head to head competition at Caterpillar's Edward Demonstration Facility in Peoria, Illinois, is discussed, including the key technology development outcomes resulting from this portion of the competition. The phase III competition consists of both virtual and construction subcompetitions. Virtual construction asks teams to render high fidelity architectural models of a habitat and all the accompanying information required for construction of the pressure retaining and load bearing portions of the structure. In construction phase III, teams are asked to scale up their printing systems to produce a 1/3 scale habitat on-site at Caterpillar. The levels of the phase III construction competition (which include printing of a foundation and printing and hydrostatic testing of a habitat element) are discussed. Phase III construction also has an increased focus on autonomy, as these systems are envisioned for robotic precursor missions which would buildup infrastructure prior to the arrival of crew. Results of the phase III competition through July 2017 (which includes virtual construction level 1) are discussed. This Centennial Challenge enables an assessment of the scaleability and efficacy of various processes, material systems, and designs for planetary construction. There are also near-term terrestrial applications, from disaster response to affordable housing and infrastructure refurbishment, for these technologies

Summary Report on Phase I and Phase II Results From the 3D Printing in Zero-G Technology Demonstration Mission

In-space manufacturing seeks to develop the processes, skill sets, and certification architecture needed to provide a rapid response manufacturing capability on long-duration exploration missions. The first 3D printer on the Space Station was developed by Made in Space, Inc. and completed two rounds of operation on orbit as part of the 3D Printing in Zero-G Technology Demonstration Mission. This Technical Publication provides a comprehensive overview of the technical objections of the mission, the two phases of hardware operation conducted on orbit, and the subsequent detailed analysis of specimens produced. No engineering significant evidence of microgravity effects on material outcomes was noted. This technology demonstration mission represents the first step in developing a suite of manufacturing capabilities to meet future mission needs

Cytoskeletal Changes During Adhesion and Release: A Comparison of Human and Nonhuman Primate Platelets

The organization of cytoskeletal proteins in whole-mount adherent platelets from African green monkeys and normal human volunteers has been studied by SEM, high vacuum electron microscopy (HVEM) and conventional (120 kV) electron microscopy. We describe three distinct organizational zones, the Central Matrix, the Trabecular Zone and the Peripheral Web in spread platelets from both sources. The Central Matrix is an ill-defined superstructure of 80-100 Å filaments of short length which enshrouded the granules, dense bodies, mitochondria and elements of the open-channel and dense-tubular systems. The latter, identified through the use of peroxidase cytochemistry with the whole mounts, is an anastomosing network of elongate saccules having diameters of 600-1200 Å. The Trabecular Zone, which encircles the Central Matrix, contains 165, 80-100 and 30-50 Å filaments in an open lattice of irregular lattice spacing. The outermost region of the cells, the Peripheral Web, is comprised of 70 Å filaments organized in a honeycomb lattice with center to center spacing in the range 150-300 Å. This pattern for the spread cells is not consistently observed in cells during the early stages of adhesion; therefore, correlations of SEM and TEM observations are made for the various stages of adhesion/activation

Summary Report on Phase I Results from the 3D Printing in Zero G Technology Demonstration Mission, Volume I

Human space exploration to date has been confined to low-Earth orbit and the Moon. The International Space Station (ISS) provides a unique opportunity for researchers to prove out the technologies that will enable humans to safely live and work in space for longer periods of time and venture beyond the Earth/Moon system. The ability to manufacture parts in-space rather than launch them from Earth represents a fundamental shift in the current risk and logistics paradigm for human spaceflight. In September 2014, NASA, in partnership with Made In Space, Inc., launched the 3D Printing in Zero-G technology demonstration mission to explore the potential of additive manufacturing for in-space applications and demonstrate the capability to manufacture parts and tools on orbit using fused deposition modeling. This Technical Publication summarizes the results of testing to date of the ground control and flight prints from the first phase of this ISS payload

Observation of discrete, vortex light bullets

We report the first experimental observation of vortex light bullets that are discrete, spatiotemporal, solitary waves with orbital angular momentum. We analyze conditions for their existence and investigate their rich properties and dynamics. Vortex light bullets are excited in fiber arrays with spatially shaped femtosecond pulses and analyzed with a spatiotemporal cross correlator. Most importantly, we find that they have entirely new stability properties, being robust against considerable degrees of perturbation in a limited range of energies. All experimental findings are backed up by rigorous simulations, giving further insight into the rich dynamics of vortex light bullets

Summary Report for the Technical Interchange Meeting on Development of Baseline Material Properties and Design Guidelines for In-Space Manufacturing Activities

NASA Marshall Space Flight Center (MSFC) and the Agency as a whole are currently engaged in a number of in-space manufacturing (ISM) activities that have the potential to reduce launch costs, enhance crew safety, and provide the capabilities needed to undertake long-duration spaceflight. The recent 3D Printing in Zero-G experiment conducted on board the International Space Station (ISS) demonstrated that parts of acrylonitrile butadiene styrene (ABS) plastic can be manufactured in microgravity using fused deposition modeling (FDM). This project represents the beginning of the development of a capability that is critical to future NASA missions. Current and future ISM activities will require the development of baseline material properties to facilitate design, analysis, and certification of materials manufactured using in-space techniques. The purpose of this technical interchange meeting (TIM) was to bring together MSFC practitioners and experts in materials characterization and development of baseline material properties for emerging technologies to advise the ISM team as we progress toward the development of material design values, standards, and acceptance criteria for materials manufactured in space. The overall objective of the TIM was to leverage MSFC's shared experiences and collective knowledge in advanced manufacturing and materials development to construct a path forward for the establishment of baseline material properties, standards development, and certification activities related to ISM. Participants were asked to help identify research and development activities that will (1) accelerate acceptance and adoption of ISM techniques among the aerospace design community; (2) benefit future NASA programs, commercial technology developments, and national needs; and (3) provide opportunities and avenues for further collaboration

Polarization Measurements During Electron Cyclotron Heating Experiments in the DIII-D Tokamak

The polarization of the launched electron cyclotron wave has been optimized for coupling to the X-mode by adjusting the inclination of grooved mirrors located in two consecutive mitre bends of the waveguide. The unwanted O-mode component of the launched beam can be positively identified by the difference in the power deposition profiles between X-mode and O-mode. The optimal polarization for X-mode launch is in good agreement with theoretical expectations

The DIII-D 3 MW, 110 GHz ECH System

Three 110 GHz gyrotrons with nominal output power of 1 MW each have been installed and are operational on the DIII-D tokamak. One gyrotron is built by Gycom and has a nominal rating of 1 MW and a 2 s pulse length, with the pulse length being determined by the maximum temperature allowed on the edge cooled Boron Nitride window. The second and third gyrotrons were built by Communications and Power Industries (CPI). The first CPI gyrotron uses a double disc FC-75 cooled sapphire window which has a pulse length rating of 0.8 s at 1 MW, 2s at 0.5 MW and 10s at 0.35 MW. The second CPI gyrotron, utilizes a single disc chemical-vapor-deposition diamond window, that employs water cooling around the edge of the disc. Calculation predict that the diamond window should be capable of full 1 MW cw operation. All gyrotrons are connected to the tokamak by a low-loss-windowless evacuated transmission line using circular corrugated waveguide for propagation in the HEl 1 mode. Each waveguide system incorporates a two mirror launcher which can steer the rf beam poloidally from the center to the outer edge of the plasma. Central current drive experiments with the two gyrotrons with 1.5 MW of injected power drove about 0.17 MA. Results from using the three gyrotron systems will be reported as well as the plans to upgrade the system to 6 MW

Polarization, propagation, and deposition measurements during ECCD experiments on the DIII-D tokamak

The power deposition profiles for different poloidal and toroidal launch angles have been determined by modulating the ECH power and measuring the electron temperature response. The peak of the measured power density follows the poloidal steering of the ECH launcher, and perpendicular launch gives a narrower deposition profile than does oblique (current drive) launch. The difference in wave refraction between X-mode and O-mode allows positive identification of an unwanted O-mode component of the launched beam