Welding and Additive Manufacturing Approaches for Space-Based Assembly, Manufacturing and Repair
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electron beam, metal, weld, additive manufacturing↗
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Factories-in-Space for Servicing, Assembly, & Manufacturing
Space 2.0 is a promising frontier for scientific exploration and the advancement of commerce, security, and technology. To effectively harness this potential, it is imperative to establish a multifunctional, resilient, and sustainable infrastructure that enables the maintenance and production of space-based systems. This capability is a driver for mission success on-orbit and for interplanetary travel to other celestial bodies. Central to this infrastructure is the establishment of orbital manufacturing facilities, referred to as 'factories-in-space' (FiS), which serve as critical nodes in the supply chain for the servicing, assembly, and production of systems essential for space-based operations. This paper presents a framework for understanding the key principles and design considerations underpinning FiS.
Technology↗
Manufacture, assembly, and delivery of beryllium test panels
Details of the fabrication and assembly of two 99 cm by 99 cm (39 in. by 39 in.) beryllium heat shield test panels are presented. Each panel consists of two hat-stiffened, formed skins which overlap a transverse slip joint at the center of the panel; clips join the two skins at the slip joint, and continuous standoffs are provided at the ends of the panel. The hat-stiffeners are joined to the skin by furnace-brazing, using the braze alloy BAg 18. The parts are generally 0.051 cm (0.020 in.) thick. Tools used to form the detail parts are shown, together with the results of preliminary forming and brazing trials to verify processing techniques. Problems encountered in the manufacture of the panels are discussed.
Source record↗
Evaluating Manufacturing and Assembly Errors in Rotating Machinery to Enhance Component Performance
Manufacturing and assembly phases play a crucial role in providing products that meet the strict functional specifications associated with rotating machinery components. The errors resulting during the manufacturing and assembly of such components are correlated with the vibration and noise emanating from the final system during its operational lifetime. Vibration and noise are especially unacceptable elements in high-risk systems such as helicopters, resulting in premature component degradation and an unsafe flying environment. In such applications, individual components often are subject to 100% inspection prior to assembly, as well as during operation through rigorous maintenance, resulting in increased product development cycles and high production and operation costs. In this work, we focus on providing designers and manufacturing engineers with a technique to evaluate vibration modes and levels for each component or subsystem prior to putting them into operation. This paper presents a preliminary investigation of the correlation between vibrations and manufacturing and assembly errors using an experimental test rig, which simulates a simple bearing and shaft arrangement. A factorial design is used to study the effects of: 1) different manufacturing instances; 2) different assembly instances; and, 3) varying shaft speeds. The results indicate a correlation between manufacturing or assembly errors and vibrations measured from accelerometers. Challenges in developing a tool for DFM are identified, followed by a discussion of future work, including a real-world application to helicopter transmission vibrations.
Tumer, Irem Y.↗
On-orbit/On-surface Servicing, Assembly, and Manufacturing (OSAM) Architecture Simulation System (OASiS)
On-orbit/on-surface servicing, assembly, and manufacturing (OSAM) –recently renamed“in-space servicing, assembly, and manufacturing”(ISAM) –will aid in the development of vital research-enabling structuresin space, such as the In-space Assembled Telescope, the Lunar Gateway, and the Lunar Safe Haven. As these structures become larger and more complex, developers will need new methods for verifying and validating their OSAM mission architectures at full-scale prior to launch, without paying for extensive facility upgrades or additional hardware prototypes. Under the OSAM Architecture Simulation System (OASiS) project, modular OSAM modeling and simulation capabilities were developed to help rapidly prototype and evaluate OSAM technologies and operational concepts.Theywerethenusedto demonstrate and evaluate data from the simulation of a simpleOSAM operation against ananaloghardware setup. Using collected test data, the teamevaluatedthe accuracy of the simulation environment against the behavior of real hardwareandgainedinsight on how to further improve OSAM modeling and simulation. With thesenewcapabilities and many more to come, developers will be able to test complex OSAM operations on multiple scales, iterate on technology designs faster, achieve higher operational accuracy, and ultimately reduce mission development costs. A comprehensive, high-fidelity simulation environment will ensure the successful servicing, assembly, and manufacturing of structures that help us study and explore our universe.
isam↗
On-orbit Servicing, Assembly and Manufacturing (OSAM) Near-Term in-Space Developmental Test Persistent Platform: ESPA-Star Based Implementation
Roundtable Session on In-Space Developmental Test: Springboard for Rapid Development. Presentation is a brief description of the On-orbit Servicing Assembly & Manufacturing (OSAM) national initiative & using standard EELV Secondary Payload Adapters (ESPAs) as the core building block to construct an ESPA-Star based implementation for an iSDT persistent platform in space.
Persistent Platform↗
Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing
NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.
Manufacturing↗
Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing
NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.
Robotics↗
Teleoperation and Visualization Interfaces for Remote Intervention in Space
Approaches to robotic manufacturing, assembly, and servicing of in-space assets range from autonomous operation to direct teleoperation, with many forms of semi-autonomous teleoperation in between. Because most approaches require one or more human operators at some level, it is important to explore the control and visualization interfaces available to those operators, taking into account the challenges due to significant telemetry time delay. We consider one motivating application of remote teleoperation, which is ground-based control of a robot on-orbit for satellite servicing. This paper presents a model-based architecture that: 1) improves visualization and situation awareness, 2) enables more effective human/robot interaction and control, and 3) detects task failures based on anomalous sensor feedback. We illustrate elements of the architecture by drawing on 10 years of our research in this area. The paper further reports the results of several multi-user experiments to evaluate the model-based architecture, on ground-based test platforms, for satellite servicing tasks subject to round-trip communication latencies of several seconds. The most significant performance gains were obtained by enhancing the operators’ situation awareness via improved visualization and by enabling them to precisely specify intended motion. In contrast, changes to the control interface, including model-mediated control or an immersive 3D environment, often reduced the reported task load but did not significantly improve task performance. Considering the challenges of fully autonomous intervention, we expect that some form of teleoperation will continue to be necessary for robotic in-situ servicing, assembly, and manufacturing tasks for the foreseeable future. We propose that effective teleoperation can be enabled by modeling the remote environment, providing operators with a fused view of the real environment and virtual model, and incorporating interfaces and control strategies that enable interactive planning, precise operation, and prompt detection of errors.
space robotics↗
A study of psychrophilic organisms isolated from the manufacture and assembly areas of spacecraft to be used in the Viking mission
The sampling of soils from the manufacture and assembly areas of the Viking spacecraft is reported and the methodology employed in the analysis of these samples for psychrophilic microorganisms, and temperature studies on these organisms is outlined. Results showing the major types of organisms and the percentage of obligate psychrophiles in each sample are given and discussed. Emphasis in all areas is toward application of these results to the objectives of the planetary quarantine program.
Foster, T. L.↗
In-space Servicing, Assembly, and Manufacturing (ISAM) State of Play - 2024 Edition
This annual document characterizes the current state of in-space servicing, assembly, and manufacturing.
Dale Arney↗
Ideas For Infusing In-Space Servicing, Assembly and Manufacturing Concepts into Nuclear Electric Propulsion Architectures
NASA is currently investigating nuclear electric propulsion (NEP) for human Mars transport within the space nuclear propulsion portfolio. NEP spacecraft have the following characteristics, they: 1) include very large structures (~100-meter length); 2) are comprised of many components/modules; and 3) have very long lifetimes (e.g., 50 years for fuel rods). Thus, NEP spacecraft can be classified as a “persistent asset,” which is any zero-g or planetary surface system that benefits from in-space assembly (ISA) or multiple visits for servicing, repairs, and upgrades. NEP spacecraft will benefit from taking advantage of, and incorporating, In-space Servicing, Assembly, and Manufacturing (ISAM) capabilities in the spacecraft architecture from the onset, enabling system maintenance, repair, and evolution. ISA has a long history of being proposed for, and studied as, a means for achieving large systems in space. More recently, the benefits of ISA have been recognized by NASA, the Department of Defense (DOD), other government agencies, and commercial space companies, and thus, ISAM is being actively pursued at a national level. Past and current strategies for achieving large structures in space have relied largely on two strategies; the first is to launch monolithic structures (designed to meet launch vehicle requirements for payload size and mass) that are docked or berthed to other monolithic structures on-orbit to form a larger structure (e.g., the International Space Station [ISS]); the second is folding and packaging large structures to fit inside a payload fairing and deploying the full-sized structure (unaided) once on-orbit (e.g., the James Webb Space Telescope [JWST]). To date, conceptual architecture studies performed for NEP spacecraft capable of human-rated Mars transport have only included a combination of the two previously mentioned strategies. This paper will propose ideas for infusing ISAM strategies into NEP vehicle architectures that leverage existing and near future technologies and enable the resulting NEP systems to be realized in a more time- and cost-efficient manner.
in-space assembly↗
In-space Servicing, Assembly, and Manufacturing (ISAM) State of Play 2022 Edition
The future of spaceflight will yield increasingly more ambitious missions to support civil, national security, and commercial space sectors. Achieving these ambitious missions is not feasible using the traditional paradigm of launching an integrated, fully functioning system on a single launch vehicle. For example, science and human exploration missions will desire payloads that are larger than any foreseeable launch vehicle fairing, national security missions will require persistent assets that are mobile and resilient, and commercial space missions will require cost-effective ways to update to the latest technology on orbit. In-space Servicing, Assembly, and Manufacturing (ISAM) can vastly expand the performance, availability, and lifetime of space systems compared to the traditional paradigm of launching an asset with no intent to ever touch it again. ISAM capabilities foster an ecosystem that changes the space operations paradigm, creating the foundation for sustainable exploration and serving as a multiplier for other capabilities like space logistics, power generation, and reusability. Previous achievements in ISAM have enabled ambitious human and robotic space missions. NASA’s International Space Station (ISS) operations and maintenance, servicing missions of the Hubble Space Telescope (HST), and Northrop Grumman’s Mission Extension Vehicle (MEV) demonstrate the dramatic operational missions that can be achieved using ISAM capabilities. Many current and upcoming flight demonstrations are advancing areas that will enable the next generation of civil, national security, and commercial space missions. This document describes the current state of ISAM missions, capabilities, and developments. Compiling and organizing the available ISAM capabilities will help mission designers incorporate ISAM technologies into their concepts, create the starting point for technology development plans and roadmaps, and provide technologists a survey of the field they are developing. This document divides the ISAM capabilities into 11 capability areas that describe the functions or activities that would be performed in space using ISAM. This version of the ISAM State of Play is part of a continuing journey to encourage the use of ISAM capabilities in space. Compiling and organizing the current state of ISAM provides a simple resource for those working in the ISAM ecosystem to ensure that the advancements being made build upon the investments of the past. The state of play is ever changing as new capabilities are developed, and this document will be periodically updated to ensure that it is relevant to those who need it in the future.
ISAM↗
Enabling A New Era of Exploration: In-space Servicing, Assembly, and Manufacturing at NASA's Goddard Space Flight Center
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ISAM↗
ASCEND: On-orbit/On-surface Servicing, Assembly, and Manufacturing (OSAM) Architecture Simulation System (OASiS)
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in-space assembly↗
Human Factors Support for On-Orbit Servicing, Assembly and Manufacturing Mission 1 (OSAM-1)
The NASA Engineering and Safety Center (NESC) Human Factors Technical Discipline Team was requested by the Satellite Servicing Projects Division at Goddard Space Flight Center to provide support in assessing the design of the On-Orbit Servicing, Assembly and Manufacturing Mission 1 (OSAM-1) Mission Operations Center in light of concerns about overcrowding and potential for distractions, as well as assistance in creating a Human-Machine Interface style guide for OSAM-1 user interface design. This report contains the outcome of the NESC assessment.
On-Orbit Servicing, Assembly and Manufacturing Mis↗
Automated array assembly
Manufacturing techniques are evaluated using expenses based on experience and studying basic cost factors for each step to evaluate expenses from a first-principles point of view. A formal cost accounting procedure is developed which is used throughout the study for cost comparisons. The first test of this procedure is a comparison of its predicted costs for array module manufacturing with costs from a study which is based on experience factors. A manufacturing cost estimate for array modules of $10/W is based on present-day manufacturing techniques, expenses, and materials costs.
Williams, B. F.↗
Ideas for Infusing In-Space Servicing, Assembly, and Manufacturing Concepts into Nuclear Electric Propulsion Architectures
NASA is currently investigating nuclear electric propulsion (NEP) for human Mars transport within the space nuclear propulsion portfolio. NEP spacecraft have the following characteristics, they: 1) include very large structures (~100-meter length); 2) are comprised of many components/modules; and 3) have very long lifetimes (e.g., 50 years for fuel rods). Thus, NEP spacecraft can be classified as a “persistent asset,” which is any zero-g or planetary surface system that benefits from in-space assembly (ISA) or multiple visits for servicing, repairs, and upgrades. NEP spacecraft will benefit from taking advantage of, and incorporating, In-space Servicing, Assembly, and Manufacturing (ISAM) capabilities in the spacecraft architecture from the onset, enabling system maintenance, repair, and evolution. ISA has a long history of being proposed for, and studied as, a means for achieving large systems in space. More recently, the benefits of ISA have been recognized by NASA, the Department of Defense (DOD), other government agencies, and commercial space companies, and thus, ISAM is being actively pursued at a national level. Past and current strategies for achieving large structures in space have relied largely on two strategies; the first is to launch monolithic structures (designed to meet launch vehicle requirements for payload size and mass) that are docked or berthed to other monolithic structures on-orbit to form a larger structure (e.g., the International Space Station [ISS]); the second is folding and packaging large structures to fit inside a payload fairing and deploying the full-sized structure (unaided) once on-orbit (e.g., the James Webb Space Telescope [JWST]). To date, conceptual architecture studies performed for NEP spacecraft capable of human-rated Mars transport have only included a combination of the two previously mentioned strategies. This paper will propose ideas for infusing ISAM strategies into NEP vehicle architectures that leverage existing and near future technologies and enable the resulting NEP systems to be realized in a more time- and cost-efficient manner.
in-space assembly↗