Low Power Multi-Mode In-Space Metals and Composites Joining

Abstract

Traditional spacecraft assembly on Earth imposes significant constraints on size, design, and cost due to the limitations of launch vehicles and the need for ruggedized components. On-orbit assembly (OOA) overcomes these challenges, enabling the deployment of larger and more advanced structures and enhancing scientific, commercial, and national security missions. This work introduces a novel approach to OOA through energy-efficient, multi-mode joining technologies for metals and composites, addressing the limitations of existing methods. The Resonance Assisted Deposition (RAD) technique is a groundbreaking method for metal joining that operates with less than 300W power and achieves high-strength bonds without heating or melting. Using ultrasound energy, RAD facilitates atomic diffusion for solid bonding, enabling robust on-orbit repair and assembly. Terrestrial trials demonstrate nearly bulk material density and strength for aluminum alloys and successful hetero-material bonding (e.g., Ni-Al, Cu-Al). For composite materials, the Laser-assisted Fused Filament Fabrication (LF3) technique offers over 80% bulk strength for high-temperature PEEK polymers, achieving isotropic properties through additive extrusion and laser heating. LF3 enhances energy efficiency, ductility, and crystallinity, enabling diverse in-space composite joining and repair. Integrating RAD and LF3 within ML-enabled robotic systems promises transformative impacts on space logistics, enabling advanced assembly, repair, and service capabilities for sustainable space operations. This article uses a V-slot design to present the application of RAD and LF3 techniques for material joining.