Laser Beam Welding of CubeSat 1U Structure Parts Obtained by Powder Bed Fusion

This study contributes to a possible methodology for manufacturing CubeSats using additive manufacturing and laser beam welding. Titanium connectors were constructed by selective laser melting and electron beam melting and characterized from a topological point of view. The connectors can be joined to titanium tubes for the construction of CubeSats via laser spot welding. The fiber laser welds exhibited full penetration using pulses with 400 J of energy. The welds showed titanium acicular martensite grains with recesses and pores. The average hardness of the cast zone was 350 HV, which is close to the hardness of the connectors (400 HV) and more rigid than that of the tubes (100 HV). Spot welding has proven to be useful in resisting forces above 2000 N, which is sufficient for CubeSat frame space applications.