Thales Alenia Space: the successful bet of the construction of space stations in the assembly line

As the world leader in pressurized modules, and involved in the development of several space stations and vehicles, Thales Alenia Space is improving its production tools in order to double its production. It is equipped with a new friction stir welding (FSW) bench. Information that could be enough on its own. But, the interview with Tiziano Pegorin, director of production and technologies at TAS-Italy, explains why this announcement is much more interesting than it seems.

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For nearly 50 years, the company Thales Alenia Space (TAS) has been building pressurized modules in Turin, Italy, which has enabled it to acquire know-how unique in the world. The company is today the world reference as well as an essential partner for all human exploration missions to deep space. After having produced more than half of the pressurized modules for the International Space Station, Thales has begun developing modules for future space stations. ESA chose it to build two of the three European modules of the Gateway (I-HAB and Esprit) and Northrop Grumman entrusted it with the construction of the pressurized compartment of the Halo logistics and housing module (Habitation And Logistics Outpos).

Thales Alenia Space was also chosen by Axiom to build the two pressurized modules of the Axiom segment of the Space Station. These will be attached to the Harmony module (junction node), thus creating a new space reserved for Axiom Space which will be able to market this inhabited part of the ISS. As part of its plan for the economic development of low Earth orbit and to prepare for the post-ISS period, NASA is funding several space station project studies, including that of Northrop Grumman, which plans to use pressurized modules derived from the cargo ship. Cygnus which are currently manufactured by Thales Alenia Space.

And it is precisely in Turin, where the TAS pressurized modules are designed and built, that Futura met Tiziano Pegorin, Director of Production and Technology, Platform & Integration Competence Center, Thales Alenia Space Italy. And if we went to the Italian premises of TAS, it was to discover a new bench for friction-stir welding (FSW - Friction Stir Welding). A process that Thales Alenia Space is the only company in Europe to use. It will make it possible to double the production capacity of pressurized modules. And therefore to meet the high demand.

The new Friction Stir Welding (FSW) bench will double the production capacity of pressurized modules. © Thales Alenia Space

Let Tiziano Pegorin introduce us to the new Friction Stir Welding (FSW) bench.

What are the technological and economic advantages of your new FSW process compared to your main competitors?

Tiziano Pegorin: We can reduce the welding cost by 30-40% compared to the typical fusion welding process. In addition, the welding schedule is also reduced by about 30-40% and it is more stable because it is less dependent on possible faults, requiring repairs, which are much more frequent and difficult to manage in old welding technologies. Finally, the performance of the seals is much higher and close to that of the original base material, which has advantages in terms of quality, cost and lead time.

We used to say that TAS is the world leader in pressurized modules. This new Friction Stir Welding (FSW) bench should double your pressurized module production capacity. Does it give you a very significant lead to the point of becoming the sole contact for space projects for the production of pressurized modules?

Tiziano Pegorin: If we limit ourselves to Europe, it is certain that TAS is the only player in this field. If we consider the world scenario, Nasa also has a large FSW factory, the Michoud Assembly Facility, used, for example, for the production of the Orion vehicle. Space-X also has this technology for the products it delivers. The position of TAS, in any case, is such that it is almost the sole interlocutor of the major American space companies in competition with SpaceX for NASA contracts (Northrop, Sierra Space, Nanorack, Dynetics, Boeing, Lockheed). In fact, TAS is, or has been, recently in discussions with most of them for the potential supply of pressurized elements.

See alsoThales Alenia Space will build the two European modules of NASA's lunar space station. Interview

What will this new bench achieve that the previous one put into service in 2015 could not do?

Tiziano Pegorin: When it comes to pressurized parts, Friction Stir Welding doesn't introduce many more new production possibilities than Fusion Welding was able to support. The FSW process makes it possible to do things faster, better and at a lower cost. A delta ability would be to weld alloys that are not acceptable for fusion techniques, or to weld dissimilar parts (made of 2 different alloys). However, these peculiarities have not yet been exploited due to the poor balance between the increased costs of new materials and the limited technical advantages. For example, aluminum and lithium alloys could be a breakthrough, but the cost is extremely high compared to the benefits.

What are the new challenges expected for lunar and Martian exploration as well as for the commercialization of space?

Tiziano Pegorin: Mainly, the time to market, the costs and the flexibility of the technical solutions which are of paramount importance to remain on the market with a leading position. Today, the time to market for new products is extremely reduced compared to 10 years ago, and so are the costs. We welded the first batch of 9 Cygnus PCMs in 2010 with plasma welding and at that time we had to reduce the manufacturing time and cost by more than 30% to obtain the second batch of 9 pieces with friction stir welding. For lunar exploration, the deadlines are getting shorter and shorter. In fact, the second welding plant was installed to meet these tight deadlines.

See alsoIn pictures: the manufacture of the future Cygnus space cargo ship

The pressurized modules are cylindrical in shape. Will this new bench allow you to produce pressurized modules of different shapes? For example, L-shaped, or with a junction node or docking ports already soldered to the module?

Tiziano Pegorin: The welding machine is a 5-axis machine that can weld complex shapes if needed, not just cylindrical or linear; however, the shapes must be compatible not only with the manufacturing possibilities but also with the constraints of the launchers which do not allow very “strange” volumes. In addition, to weld complex configurations, you need complex and expensive tools, and time to be qualified. All these parameters must be managed together to find the right compromise.

“We have made significant progress in our ability to manufacture 'faster, better and cheaper'

Compared to the bench that allowed you to build the ATV, how would you summarize the evolution of your development and construction methods and how do you envisage those for the future?

Tiziano Pegorin: So far comparing ATV manufacturing with VPPA and Cygnus/Axiom/Halo etc. with the FSW we can say that we have made significant progress in our ability to manufacture "faster, better and cheaper", but the basic design solution of the structure has not changed, the modules still being based on a large cylindrical aluminum volume. This is true for the whole panorama of manned exploration in the world. The metallic solution guarantees the right level of performance, security and, in particular, confidence.

In the future, new materials such as composites are already being evaluated and tested and they could replace all or part of the metallic solutions. However, the road to this solution in orbit for a long time with a human being inside is still long, because we must reach not only an acceptable technical solution, but also the confidence that it will work for years in orbit where it It is not possible to carry out periodic structural inspections as for aircraft. So I think we still have room in the years to come to improve and optimize metal solutions.

Now that this facility is up and running, what are the next development steps?

Tiziano Pegorin: This is the second plant we are commissioning and we are now focused on meeting our customers' demand in the next two or three years. In the meantime, we will monitor the evolution of the market and we will see if the opportunities will be there... We will have to decide if we further strengthen our capacity or if we invest in new solutions, like the composite mentioned before, in order to reach our objective: to remain at the top of the world ranking for these products.

Northrop Grumman's space station project will use pressurized modules derived from the Cygnus freighter that are currently manufactured by Thales Alenia Space. In the box, top left, the 18th ^Cygnus being manufactured in the Turin factory of Thales Alenia Space. © Northrop Grumman

To know more

Thales Alenia Space: interview with the world leader in pressurized modules for astronauts for 50 years!

Article by Rémy Decourt published on 15/10/2020

When Thales Alenia Space (TAS) was chosen to supply the two main European modules of NASA's Gateway (Artemis program), Futura met Walter Cugno. Director of science and exploration activities at Thales Alenia Space, he explains how his company has become the world reference for the construction of pressurized modules for space stations and for many other applications. Exciting.

For nearly 50 years, Thales Alenia Space (TAS) has been building pressurized modules for astronauts. It has just been selected by ESA to provide two modules for the future lunar space station called Gateway. Meeting with Walter Cugno, director of science and exploration activities at Thales Alenia Space, who was kind enough to answer our questions.

Futura: Is Thales Alenia Space becoming the world reference for space stations?

Walter Cugno: TAS is certainly one of the major references for the development of space stations, whether designed for low orbit, Cis-lunar orbit, or even for the surface of the Moon, and tomorrow for Mars . In the world, there are very few players capable of building them. And we are one of them! For nearly 50 years, our capabilities and performance have been demonstrated with the supply of numerous pressurized elements of all types (housing, functional junction nodes, freight transport, human landing system...), for different projects and applications on behalf of space agencies or within the framework of B2B partnerships.

Thales Alenia Space is therefore:

Futura: You have built several generations of pressurized modules. How would you sum up each generation in terms of construction techniques, use, feedback, skills acquired...

Walter Cugno: Our company started developing these elements almost 50 years ago with the first European manned pressurized module, Spacelab, one of the first space laboratories. The different stages or generations of modules have been driven by the need to provide the right environment for astronauts to operate in space and exploit the opportunities offered by this new environment. Of course, the ultimate goal is the development of humanity's ability to explore and develop in space, and to exploit space resources. These are the main drivers to consider with the development of required technologies and available means of transport.

In Europe, mainly under the leadership of Germany and Italy, we started the development of the Spacelab module to provide increased space shuttle capacity in terms of the pressurized volume available for astronauts to carry out research in the space. Spacelab gave us the knowledge and experience needed to develop a space station. Thus, the first phase for us was linked to the exploitation of the opportunities offered by the space shuttle to develop products and technologies aimed at supporting its operations in low orbit, and to prepare the next stage which was the provision of permanent manned infrastructure in low Earth orbit.

Walter Cugno, director of science and exploration activities at Thales Alenia Space. © Thales Alenia Space

Futura: The second generation of pressurized modules is that of the ISS?

Walter Cugno: It was the second stage, the second generation therefore. We arrive at the International Space Station after several stages of development, from a European Free Flyer type configuration, through a smaller space station involving a few countries - Freedom - and finally to the ISS with the need for habitability and of logistics pressurized volumes, a research laboratory and all support infrastructure and facilities, including freight and transport vehicles. Thanks to the investments and the vision of the Italian government and the Italian space agency, our company was ready to develop and build them as evidenced by the development of more than 40% of this exceptional space infrastructure.

Futura: The third generation will concern exploration and commercial stations?

Walter Cugno: Yes. The next generation is represented by new opportunities for the use of low Earth orbit in terms of commercialization. The Axiom commercial space station is an example of this as the Bishop Airlock is another, and at the same time the permanent return to the Moon with the development of the Gateway, the vehicles to support logistics, the human and cargo landing systems until to the manned and robotic infrastructures necessary on the surface of the Moon and then... finally the preparation to go to Mars.

Production capacities and associated technologies have of course evolved considerably over the years, as has the availability of new, more efficient materials, as well as increased knowledge of what happens during space operations thanks to feedback from astronauts. Knowledge that is normally shared with the companies involved allowing continuous improvement of these systems and the products concerned.

This continuous feedback on the performance of these elements in space - the best that needs to be done to improve quality and operability as well as to provide an ever better home and environment for the crew - is what helps us to improve ourselves and also to be more competitive. This feedback from real operations must be used correctly in order to then be creative, innovative and capable of investing in R&D and in new products by anticipating market needs, whether institutional or commercial.

Spacelab 1 installed in the payload bay of the Columbia shuttle (August 1983) for its flight in November (STS-9) on board which Ulf Merbold, ESA's first European astronaut, will embark. © Nasa

Futura: How will the experience gained with the ISS modules help you develop the Gateway and Axiom modules?

Walter Cugno: Thales Alenia Space's involvement in the lunar space station, for which we will produce the two I-HAB and ESPRIT modules, which are ESA's contribution, as well as the structure of the HALO logistics and habitat module on behalf of Northrop Grumman, adding to the development of the commercial space station Axiom, is the result of the capitalization of the expertise and knowledge acquired with the ISS program. These give us the opportunity to continuously develop our products technically and at the same time to increase our competitiveness also in terms of schedule and cost performance.

The space arena is extremely competitive even in the institutional domain, new offers of advanced products and services are continuously provided, not only by the historical companies but by new extremely innovative and aggressive players. Thus, the ISS experience is a unique opportunity to be capitalized by innovating new products from a solid historical base which includes, of course, the knowledge and culture developed by our teams which will be maintained and transferred to the new generation of engineers.

Futura: What are the "weaknesses" and "points to improve" identified on the ISS modules and which will have to be corrected for your future modules?

Walter Cugno: In fact, I won't talk about weaknesses since all these modules were developed according to customer requests and fully complied with them. There are of course many points for improvement, resulting from operating experience feedback and considering that they were all designed with the knowledge and technologies available nearly thirty years ago. It is difficult to identify all these areas. Of course, some key elements are relevant for a better use of the available volume, made possible with the new technologies in robotics, avionics, digitalization and artificial intelligence which bring more comfort to the crew and facilitate IVA operations (aircraft activities). interior of modules), EVA (extra-vehicular exits) and many other aspects. Last but not least to allow more time for the crew to perform the value-added tasks, be it R&D activities or productive activities.

We will also consider that, especially with regard to the lunar space station, the design of the modules will be improved and different due to a different and more extreme environment than that of low orbit, the distance to the Earth and the fact that this station will not be permanently occupied by crews, to name a few of the differentiators.

The future Axiom commercial space station whose pressurized modules will be built by Thales Alenia Space. © Axiom Space

Futura: What are the “technological solutions and choices” put in place for the construction of the ISS modules that will be abandoned for your future modules and replaced by others?

Walter Cugno: As previously stated, ISS modules were developed nearly thirty years ago, so future new modules will benefit from new technologies, materials and products available as well as lessons learned from ISS operations. . Some examples below:

Lunar lander project developed by Dynetics (in which Thales Alenia Space participates by supplying the pressurized cabin) for NASA. This is one of the three lunar lander projects selected by NASA, which should select one for the first two Artemis missions sent to the Moon. The other two projects are those of SpaceX and Blue Origin. © Dynetics

Futura: Beyond Axiom and the Gateway, how do you envision lunar and Martian modules, or even for manned flights beyond Mars?

Walter Cugno: The next generation of lunar modules at the start of lunar surface infrastructure development will be heavily derived from those developed for the lunar space station. Then, with the growth of our capabilities and knowledge, the following items will take advantage of the exploitation of the Moon's resources to be manufactured in situ and could use the lunar lava tubes for better protection against the lunar environment. These modules will be the core of the famous "lunar village" and, in any case, of the infrastructures necessary to allow Man to stay and operate permanently on the Moon. The Martian modules and relevant infrastructure will take advantage of what will be learned on the Moon, of course, making all the modifications and improvements necessary to bring them to Mars and to withstand the different and even more difficult Martian environment.

Human flight beyond Mars today is only something to excite our imagination but quite remote based on today's knowledge. The challenge today to send human missions to Mars is already very difficult and at the limit of our current knowledge and capabilities. In any case, the only limit to humanity is the imagination. However, our thoughts and imaginations are the only real limits to our possibilities... and to the laws of physics.

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External linkThales Alenia SpaceRelated definitionsA volume: what is it?SpaceX, what is?Definition of "duration"What is Columbia?Friction: what is it?