Manufacturing in space poses considerable challenges, despite many of the techniques resembling those utilized on Earth. Methods such as riveting, bolting, and welding are relevant, with the latter first attempted by Soviet cosmonauts over fifty years ago. Recently, NASA has revealed a partnership focused on in-space welding, highlighting the exploration of how reduced gravity and different atmospheric conditions influence weld quality.
The Soviets were the first to achieve success in space welding, executing the initial effective weld during the Soyuz-6 mission in 1969. NASA later investigated welding techniques during experiments on the Skylab space station in 1973 and, in 1984, accomplished the first (and only) welding in open space during an EVA on the Salyut-7 mission. Presently, NASA is looking into fiber laser-based welding, as outlined in a series of presentation documents. Preliminary tests have been carried out during parabolic flight maneuvers since August 2024, with further experiments slated for space.
In 1996, NASA collaborated with the E.O. Paton Welding Institute based in Kyiv, Ukraine, to work on a project about in-space welding as part of the ISWE initiative, which was meant for testing on the Mir space station; however, unforeseen complications ultimately led to the cancellation of the project. More recently, the European Space Agency (ESA) has been conducting experiments with in-space welding, reapplying the electron-beam welding (EBW) technique from the 1969 Soyuz-6 mission. EBW provides consistent control over welds in the high-vacuum environment typical of space.
This brings up an important question: why choose laser beam welding (LBW) instead of EBW? While EBW has certain limitations regarding atmospheric conditions and material suitability, its primary advantage lies in its lower power consumption compared to LBW. As LBW experiments progress further into space, they could pave the way for innovative construction techniques necessary for building structures and habitats not only in space but also on the surfaces of the Moon and Mars.
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