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By Space Force
Space Delta 5 and the Combined Space Operations Center hosted a three-day working group to collaborate on current efforts for developing a shared Space Common Operational Picture.
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By NASA
4 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
By Wayne Smith
As NASA plans for humans to return to the Moon and eventually explore Mars, a laser beam welding collaboration between NASA’s Marshall Space Flight Center in Huntsville, Alabama, and The Ohio State University in Columbus aims to stimulate in-space manufacturing.
Scientists and engineers from NASA’s Marshall Space Flight Center, participating in the laser beam welding study in August, stand in front of the parabolic plane used for testing. From left, Will Evans, Louise Littles, Emma Jaynes, Andrew O’Connor, and Jeffrey Sowards. Not pictured: Zachary Courtright.Casey Coughlin/Starlab-George Washington Carver Science Park The multi-year effort seeks to understand the physical processes of welding on the lunar surface, such as investigating the effects of laser beam welding in a combined vacuum and reduced gravity environment. The goal is to increase the capabilities of manufacturing in space to potentially assemble large structures or make repairs on the Moon, which will inform humanity’s next giant leap of sending astronauts to Mars and beyond.
“For a long time, we’ve used fasteners, rivets, or other mechanical means to keep structures that we assemble together in space,” said Andrew O’Connor, a Marshall materials scientist who is helping coordinate the collaborative effort and is NASA’s technical lead for the project. “But we’re starting to realize that if we really want strong joints and if we want structures to stay together when assembled on the lunar surface, we may need in-space welding.” The ability to weld structures in space would also eliminate the need to transport rivets and other materials, reducing payloads for space travel. That means learning how welds will perform in space.
To turn the effort into reality, researchers are gathering data on welding under simulated space conditions, such as temperature and heat transfer in a vacuum; the size and shape of the molten area under a laser beam; how the weld cross-section looks after it solidifies; and how mechanical properties change for welds performed in environmental conditions mimicking the lunar surface.
“Once you leave Earth, it becomes more difficult to test how the weld performs, so we are leveraging both experiments and computer modeling to predict welding in space while we’re still on the ground,” said O’Connor.
In August 2024, a joint team from Ohio State’s Welding Engineering and Multidisciplinary Capstone Programs and Marshall’s Materials & Processes Laboratory performed high-powered fiber laser beam welding aboard a commercial aircraft that simulated reduced gravity. The aircraft performed parabolic flight maneuvers that began in level flight, pulled up to add 8,000 feet in altitude, and pushed over at the top of a parabolic arc, resulting in approximately 20 seconds of reduced gravity to the passengers and experiments.
While floating in this weightless environment, team members performed laser welding experiments in a simulated environment similar to that of both low Earth orbit and lunar gravity. Analysis of data collected by a network of sensors during the tests will help researchers understand the effects of space environments on the welding process and welded material.
NASA Marshall engineers and scientists, along with their collaborators from Ohio State University, monitor laser beam welding in a vacuum chamber during a Boeing 727 parabolic flight. From left, Andrew O’Connor, Marshall materials scientist and NASA technical lead for the project; Louise Littles, Marshall materials scientist; and Aaron Brimmer, OSU graduate student.Tasha Dixon/Zero-G “During the flights we successfully completed 69 out of 70 welds in microgravity and lunar gravity conditions, realizing a fully successful flight campaign,” said Will McAuley, an Ohio State welding engineering student.
Funded in part by Marshall and spanning more than two years, the work involves undergraduate and graduate students and professors from Ohio State, and engineers across several NASA centers. Marshall personnel trained alongside the university team, learning how to operate the flight hardware and sharing valuable lessons from previous parabolic flight experiments. NASA’s Langley Research Center in Hampton, Virginia, developed a portable vacuum chamber to support testing efforts.
The last time NASA performed welding in space was during the Skylab mission in 1973. Other parabolic tests have since been performed, using low-powered lasers. Practical welding and joining methods and allied processes, including additive manufacturing, will be required to develop the in-space economy. These processes will repurpose and repair critical space infrastructure and could build structures too large to fit current launch payload volumes. In-space welding could expedite building large habitats in low Earth orbit, spacecraft structures that keep astronauts safe on future missions, and more.
The work is also relevant to understanding how laser beam welding occurs on Earth. Industries could use data to inform welding processes, which are critical to a host of manufactured goods from cars and refrigerators to skyscrapers.
“We’re really excited about laser beam welding because it gives us the flexibility to operate in different environments,” O’Connor said.
There has been a resurgence of interest in welding as we look for innovative ways to put larger structures on the surface of the Moon and other planets.
Andrew O’Connor
Marshall Space Flight Center materials scientist
This effort is sponsored by NASA Marshall’s Research and Development funds, the agency’s Science Mission Directorate Biological and Physical Sciences Division of the agency’s Science Mission Directorate, and NASA’s Space Technology Mission Directorate, including NASA Flight Opportunities.
For more information about NASA’s Marshall Space Flight Center, visit:
https://www.nasa.gov/marshall
Joel Wallace
Marshall Space Flight Center, Huntsville, Alabama
256.544.0034
joel.w.wallace@nasa.gov
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Last Updated Nov 07, 2024 Related Terms
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By NASA
4 Min Read Student-Built Capsules Endure Heat of Re-entry for NASA Science
The five capsules of the KREPE-2 mission are pictured on Earth prior to flight. Credits: University of Kentucky. In July 2024, five student-built capsules endured the scorching heat of re-entry through Earth’s atmosphere as part of the second Kentucky Re-Entry Probe Experiment (KREPE-2). Scientists are now analyzing the data from the KREPE-2 experiments, which could advance the development of heat shields that protect spacecraft when they return to Earth.
The mission was designed to put a variety of heat shield prototypes to the test in authentic re-entry conditions to see how they would perform. These experimental capsules, which were built by students at the University of Kentucky and funded by the NASA Established Program to Stimulate Competitive Research (EPSCoR) within NASA’s Office of STEM Engagement, all survived more than 4,000 degrees Fahrenheit during descent.
The football-sized capsules also successfully transmitted valuable data via the Iridium satellite network along their fiery journey. The trove of information they provided is currently being analyzed to consider in current and future spacecraft design, and to improve upon designs for future experiments.
“These data – and the instruments used to obtain the data – assist NASA with designing and assessing the performance of current and new spacecraft that transport crew and cargo to and from space,” said Stan Bouslog, thermal protection system senior discipline expert at NASA’s Johnson Space Center in Houston who served as the agency’s technical monitor for the project.
Taking the Plunge: Communicating Through a Fiery Descent
“The only way to ‘test like you fly’ a thermal protection system is to expose it to actual hypersonic flight through an atmosphere,” Bouslog said.
The self-contained capsules launched aboard an uncrewed Northrop Grumman Cygnus spacecraft in January 2024 along with other cargo bound for the International Space Station. The cargo craft detached from the space station July 12 as the orbiting laboratory flew above the south Atlantic Ocean. As the Cygnus spacecraft began its planned breakup during re-entry, the KREPE-2 capsules detected a signal – a temperature spike or acceleration – to start recording data and were released from the vehicle. At that point, they were traveling at a velocity of about 16,000 miles per hour at an altitude of approximately 180,000 feet.
The University of Kentucky student team and advisors watched and waited to learn how the capsules had fared.
As the capsules descended through the atmosphere, one group watched from aboard an aircraft flying near the Cook Islands in the south Pacific Ocean, where they tracked the return of the Cygnus spacecraft. The flight was arranged in partnership with the University of Southern Queensland in Toowoomba, Queensland, Australia, and the University of Stuttgart in Stuttgart, Germany. Alexandre Martin, professor of mechanical and aerospace engineering at the University of Kentucky and the principal investigator for the experiment, was on that flight.
“We flew in close to the re-entry path to take scientific measurements,” Martin said, adding that they used multiple cameras and spectrometers to observe re-entry. “We now have a much better understanding of the break-up event of the Cygnus vehicle, and thus the release of the capsules.”
Meanwhile, members of the University of Kentucky’s Hypersonic Institute had gathered at the university to watch as KREPE-2 data arrived via email. All five successfully communicated their flight conditions as they hurtled to Earth.
“It will take time to extract the data and analyze it,” Martin said. “But the big accomplishment was that every capsule sent data.”
Members of the University of Kentucky student team have begun analyzing the data to digitally reconstruct the flight environment at the time of transmission, providing key insights for future computer modeling and heat shield design.
An artist’s rendering of one of the KREPE-2 capsules during re-entry. A. Martin, P. Rodgers, L. Young, J. Adams, University of Kentucky Building on Student Success
The mission builds on the accomplishments of KREPE-1, which took place in December 2022. In that experiment, two capsules recorded temperature measurements as they re-entered Earth’s atmosphere and relayed that data to the ground.
The extensive dataset collected during the KREPE-2 re-entry includes heat shield measurements, such as temperature, as well as flight data including pressure, acceleration, and angular velocity. The team also successfully tested a spectrometer that provided spectral data of the shockwave in front of a capsule.
“KREPE-1 was really to show we could do it,” Martin said. “For KREPE-2, we wanted to fully instrument the capsules and really see what we could learn.”
KREPE-3 is currently set to take place in 2026.
The ongoing project has provided valuable opportunities for the University of Kentucky student team, from undergrads to PhD students, to contribute to spaceflight technology innovation.
“This effort is done by students entirely: fabrication, running simulations, handling all the NASA reviews, and doing all the testing,” Martin said. “We’re there supervising, of course, but it’s always the students who make these missions possible.”
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By NASA
Learn Home Integrating Relevant Science… Earth Science Overview Learning Resources Science Activation Teams SME Map Opportunities More Science Activation Stories Citizen Science 3 min read
Integrating Relevant Science Investigations into Migrant Children Education
For three weeks in August, over 100 migrant children (ages 3-15) got to engage in hands-on activities involving blueberries, pollinators, and eDNA as part of their time with The Blueberry Harvest School (BHS). BHS is a summer school program for migrant children whose families work in Washington County, Maine during the wild blueberry harvest season. The program is hosted by Mano en Mano in Milbridge, Maine. This summer, University of Maine 4-H (part of the NASA Science Activation Program’s Learning Ecosystems Northeast team) was invited to deliver enrichment programs during the school day alongside a seasoned BHS employee – an educator from the Mi’kmaq community in what is now known as Nova Scotia.
The goal of BHS is to meet the needs of youth by providing “culturally responsive, project-based learning while preventing summer learning loss and compensating for school disruptions among students” (Mano en Mano). Migrant families come to Downeast from Mi’kmaq First Nation communities in Nova Scotia and New Brunswick, southern states, and from within Maine, including Passamoquoddy communities in eastern Washington County and a Latino community in the western part of the county. Families stay to harvest blueberries anywhere from two to five weeks. With support from 4-H educators, youth surveyed the schoolyard for pollinators, investigated the parts of pollinators and flowers, and learned why blueberries are an important part of Wabanaki culture.
“BHS really becomes a home for the children while they are here. I think one of the reasons is because they are encouraged to be proud of their identity and who they are – they get to be their authentic selves. It’s a neat space where teachers and youth are speaking Mi’kmaq, Passamaquoddy, Spanish and English while supporting each other, and learning and experiencing new things.” — Gabrielle Brodek, 4-H Professional
“After completing my second year helping at Blueberry Harvest School, I loved seeing the returning faces of the kids who have been coming year after year – the kids remember you and hug you and are sad when the season is over and BHS ends.” — Jason Palomo, 4-H Professional
Resources and inspiration for these activities came from NASA Climate Kids, Gulf of Maine Research Institute’s Bees, Blueberries, and Climate Change learning module, National 4-H and ME Ag in the Classroom. On the last day youth experienced how to make a natural dye out of blueberries, a long-standing tradition in Native American culture. Our organizations continue to work together year-round, building stronger relationships and planning for Summer 2025!
The Learning Ecosystems Northeast project is supported by NASA under cooperative agreement award number NNX16AB94A and is part of NASA’s Science Activation Portfolio. Learn more about how Science Activation connects NASA science experts, real content, and experiences with community leaders to do science in ways that activate minds and promote deeper understanding of our world and beyond: https://science.nasa.gov/learn
Educator assisting two youth with paper folding instructions. Share
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Last Updated Nov 06, 2024 Editor NASA Science Editorial Team Related Terms
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