In-Space Joining and Welding of Metallic Materials for Satellite Servicing Applications

Lunar Resources, Inc. (LR) and University of Alabama at Huntsville (UAH) propose to modify LR’s pulsed electrical discharge additive manufacturing system (PE3D) to perform metal joining and welding of spacecraft components, parts and payloads on-orbit. LR is funded by the DoD to develop the PE3D,  a revolutionary manufacturing technology which is able to AM and join/weld nearly any type of metallic material. The PE3D is currently being implemented by prime aerospace companies for civil and defense programs, as well it is under trials with a number of other aerospace and construction companies for metal AM and joining. Currently, there does not exist a technology to robotically join and weld aerospace grade metals in microgravity. The PE3D utilizes a state-of-the-art, proprietary, pulse power system to deliver ultra-high efficient pulsed energy to melt ultra-high temperature metals. The pulse rate, energy output and pulse lifetime can be scaled and adjusted to deliver a targeted amount of energy onto a material allowing for orders of magnitude higher electrical efficiencies while enabling the PE3D to join/weld metals with superior microstructures and surface finishes.