The European Space Agency (ESA) has analyzed the first autonomous weld performed in space using advanced microscopy, hardness testing, and X-ray tomography at their Netherlands laboratory. This weld, made from aerospace-grade aluminum, is crucial for developing in-space manufacturing capabilities. João Gandra, an ESA Materials Engineer, highlighted that space welding differs due to microgravity, radiation, and vacuum conditions, making it essential to gather empirical data. The weld was produced by an electron beam welding gun flown aboard a SpaceX Falcon 9, marking a milestone in sustainable space construction efforts.

Strict followers of the this blog will remember my ThinkOrbital story last month. 👇
World’s First In-Space Electron Beam Welding Sets New Standards
In a groundbreaking development for space manufacturing, successfully demonstrated the use of an electron beam welding in the vacuum of space.
Weld FeedBurcin Vargel

Historically, space welding dates back to the USSR's Soyuz-6 in 1969 and later space stations, but no orbital welds were performed for four decades until this recent experiment. The electron beam welding method, which suits the vacuum of space, proved highly efficient for deep metal penetration without energy waste. ThinkOrbital, which initiated the experiment, collaborated with ESA and NASA, aiming to expand humanity’s capabilities for long-term space exploration and construction.

Comparing the in-space-made weld, seen left, to its terrestrial equivalent, right. This is the historic result of the very first autonomous welding to be performed in space, and the first ESA has been involved with. No welds have been performed in orbit for four decades – until this recent automated ThinkOrbital experiment, involving an electron beam welding gun, flown on the first stage of a SpaceX Falcon 9 launched from Cape Canaveral on 6 May.

ThinkOrbital CEO Colonel Lee Rosen emphasized the experiment's significance in advancing space technology. ESA's João Gandra added that the initiative aligns with ESA’s strategy to advance in-space manufacturing, an essential component for future missions beyond Earth. The ESA team will continue analyzing the weld samples, contributing to the development of technologies for space economy and sustainable exploration.

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Space-made weld scrutinised in ESA lab
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-made weld scrutinised in ESA lab
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