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Space-made weld scrutinised in ESA lab

Written by  Thursday, 10 October 2024 12:31
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Comparing the in-space weld to its terrestrial equivalent

ESA engineers have focused microscopes, hardness testers and an X-ray computer aided tomography machine onto a special aluminium weld just a single centimetre across – the historic result of the very first autonomous welding to be performed in space, and the first ESA has been involved with.

Space welding test on Salyut-7 in 1984
Space welding test on Salyut-7 in 1984

This means no welds have been performed in orbit for four decades – until this recent automated experiment, involving an electron beam welding gun, flown on a SpaceX Falcon 9 launched from Cape Canaveral on 6 May.

This experiment employed electron beam welding, the very same method used during the 1969 Soyuz-6 experiment. It involves directing a beam of high-velocity electrons onto the metal, so that kinetic energy is transformed into heat. Electron beam welding has the advantage of being highly controllable, penetrating deep into the metal to be welded, with no wasted energy. It can only be performed in high-quality vacuum, making electron beam welding a good fit for space. And this system may be capable not just of welding, but also cutting and 3D printing.


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