Dr. Wei Li, a professor of mechanical engineering in the Erik Jonsson School of Engineering and Computer Science at The University of Texas at Dallas ( UTD ), has begun developing a virtual platform for metal welding on the Moon.
The challenge of metal welding on the Moon
The lunar surface presents three major technical challenges for construction: extreme temperatures ranging from -200°C to 130°C, a near-absolute vacuum due to its very thin atmosphere, and gravity reduced to about one-sixth that of Earth’s. These conditions can induce defects such as cracks and fractures in metal joints if the welding process is not precisely controlled.
Dr. Li was one of six researchers nationwide selected to receive a 2024 NASA Early-Stage Innovations Program annual grant. The grant, worth up to $750,000 over three years, will allow him to develop a digital simulation platform based on multiphysics modeling. This tool will recreate the lunar thermal , mechanical , and gravitational conditions for testing various welding processes: electric arc, laser, and electron beam.
The virtual simulation will be supported by practical testing in the terrestrial environment using a custom directed energy deposition ( DED ) machine, a technology commonly used in metal additive manufacturing. Li will also explore applications in fused deposition modeling (FDM), with the potential to print non-metallic parts for space missions.
The UT Dallas team will work closely with researchers at NASA ‘s Marshall Space Flight Center , such as Dr. Fredrick Michael, to validate the results through testing in controlled environments and supported by historical data, including data from experiments conducted during Skylab missions.
Since establishing conventional welding workshops on the lunar surface is unfeasible, a viable alternative would be to transport metal components from Earth and assemble them using advanced welding techniques.
The lunar welding simulation system. Source: Jonsson School at UT Dallas
This program would allow the creation of simulated prototypes of large infrastructures that would serve as pressurized habitats or scientific modules , essential for future missions to Earth’s natural satellite or expeditions to Mars.
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Source and photo: UTD
