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In Friction Stir Welding (FSW) a rotating pin-tool inserted into a weld seam literally stirs the edges of the seam together. In this study, two flow paths are proposed that define the FWS zone. Studies using a longitudinal tungsten wire (0.0025 dia.) were used to visualize and document the material flow. The material flow path is described using a mathematical model.
Friction stir welding is a solid-phase joining, or welding process that was invented in 1991 at The Welding Institute (TWI). The process is potentially capable of joining a wide variety of aluminum alloys that are traditionally difficult to fusion weld. The friction stir welding (FSW) process produces welds by moving a non-consumable rotating pin tool along a seam between work pieces that are firmly clamped to an anvil. At the start of the process, the rotating pin is plunged into the material to a pre-determined load. The required heat is produced by a combination of frictional and deformation heating. The shape of the tool shoulder and supporting anvil promotes a high hydrostatic pressure along the joint line as the tool shears and literally stirs the metal together. To produce a defect free weld, process variables (RPM, transverse speed, and downward force) and tool pin design must be chosen carefully. An accurate model of the material flow during the process is necessary to guide process variable selection. At MSFC a plastic slip line model of the process has been synthesized based on macroscopic images of the resulting weld material. Although this model appears to have captured the main features of the process, material specific interactions are not understood. The objective of the present research was to develop a basic understanding of the evolution of the microstructure to be able to relate it to the deformation process variables of strain, strain rate, and temperature.
This paper will present the current concept using extensible Markup Language (XML) as the underlying structure for the James Webb Space Telescope (JWST) database. The purpose of using XML is to provide a JWST database, independent of any portion of the ground system, yet still compatible with the various systems using a variety of different structures. The testing of the JWST Flight Software (FSW) started in 2002, yet the launch is scheduled for 2011 with a planned 5-year mission and a 5-year follow on option. The initial database and ground system elements, including the commands, telemetry, and ground system tools will be used for 19 years, plus post mission activities. During the Integration and Test (I&T) phases of the JWST development, 24 distinct laboratories, each geographically dispersed, will have local database tools with an XML database. Each of these laboratories database tools will be used for the exporting and importing of data both locally and to a central database system, inputting data to the database certification process, and providing various reports. A centralized certified database repository will be maintained by the Space Telescope Science Institute (STScI), in Baltimore, Maryland, USA. One of the challenges for the database is to be flexible enough to allow for the upgrade, addition or changing of individual items without effecting the entire ground system. Also, using XML should allow for the altering of the import and export formats needed by the various elements, tracking the verification/validation of each database item, allow many organizations to provide database inputs, and the merging of the many existing database processes into one central database structure throughout the JWST program. Many National Aeronautics and Space Administration (NASA) projects have attempted to take advantage of open source and commercial technology. Often this causes a greater reliance on the use of Commercial-Off-The-Shelf (COTS), which is often limiting. In our review of the database requirements and the COTS software available, only very expensive COTS software will meet 90% of requirements. Even with the high projected initial cost of COTS, the development and support for custom code over the 19-year mission period was forecasted to be higher than the total licensing costs. A group did look at reusing existing database tools and formats. If the JWST database was already in a mature state, the reuse made sense, but with the database still needing to handing the addition of different types of command and telemetry structures, defining new spacecraft systems, accept input and export to systems which has not been defined yet, XML provided the flexibility desired. It remains to be determined whether the XML database will reduce the over all cost for the JWST mission.
For fifteen years, the science mission of the Hubble Space Telescope (HST) required using at least three of the six on-board rate gyros for attitude control. Failed gyros were eventually replaced through Space Shuttle Servicing Missions. The tragic loss of the Space Shuttle Columbia has resulted in the cancellation of all planned Shuttle based missions to HST. While a robotic servicing mission is currently being planned instead, controlling with alternate sensors to replace failed gyros can extend the HST science gathering until a servicing mission can be performed, and also extend science at HST's end of life. Additionally, sufficient performance may allow a permanent transition to operations with less than 3 gyros (by intentionally turning off working gyros saving them for later use) allowing for an even greater science mission extension. To meet this need, a Two Gyro Science (TGS) mode has been designed and implemented using magnetometers (Magnetic Sensing System - MSS), Fixed Head Star Trackers (FHSTs), and Fine Guidance Sensors (FGSs) to control vehicle rate about the missing gyro input axis. The development of the TGS capability is the largest re-design of HST operations undertaken, since it affects several major spacecraft subsystems, the most heavily being the Pointing Control System (PCS) and Flight Software (FSW). Additionally, and equally important, are the extensive modifications and enhancements of the Planning and Scheduling system which must now be capable of scheduling science observations while taking into account several new constraints imposed by the TGS operational modes (such as FHST availability and magnetic field geometry) that will impact science gathering efficiency and target availability. This paper discusses the systems engineering design, development, and performance of the TGS mode, now in its final stages of completion.
In friction stir welding (FSW), a rotating threaded pin tool is translated along a weld seam, literally stirring the edges of the seam together. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path or paths is required. In this study, various markers are used to trace the flow paths of the metal. X-ray radiographs record the segmentation and position of the wire. Several variations in the trajectories can be differentiated within the weld zone.
For fifteen years, the science mission of the Hubble Space Telescope (HST) required using at least three of the six on-board rate gyros for attitude control. Failed gyros were eventually replaced through Space Shuttle Servicing Missions. The tragic loss of the Space Shuttle Columbia has resulted in the cancellation of all planned Shuttle based missions to HST. While a robotic servicing mission is currently being planned instead, controlling with alternate sensors to replace failed gyros can extend the HST science gathering until a servicing mission can be performed, and also extend science at HST s end of life. Additionally, sufficient performance may allow a permanent transition to operations with less than 3 gyros (by intentionally turning off working gyros saving them for later use) allowing for an even greater science mission extension. To meet this need, a Two Gyro Science (TGS) mode has been designed and implemented using magnetometers (Magnetic Sensing System - MSS), Fixed Head Star Trackers (FHSTs), and Fine Guidance Sensors (FGSs) to control vehicle rate about the missing gyro input axis. The development of the TGS capability is the largest re-design of HST operations undertaken, since it affects several major spacecraft subsystems, the most heavily being the Pointing Control System (PCS) and Flight Software (FSW). Additionally, and equally important, are the extensive modifications and enhancements of the Planning and Scheduling system which must now be capable of scheduling science observations while taking into account several new constraints imposed by the TGS operational modes (such as FHST availability and magnetic field geometry) that will impact science gathering efficiency and target availability. This paper discusses the systems engineering design, development, and performance of the TGS mode, now in its final stages of completion.
The effects of laser peening, shot peening, and a combination of both on the fatigue life of Friction Stir Welds (FSW) was investigated. The fatigue samples consisted of dog bone specimens and the loading was applied in a direction perpendicular to the weld direction. Several laser peening conditions with different intensities, durations, and peening order were tested to obtain the optimum peening parameters. The surface roughness resulting from various peening techniques was assessed and characterized. The results indicate a significant increase in fatigue life using laser peening compared to shot peened versus their native welded specimens.
In this presentation, the results of a recent study on the effect of pin tool design for friction stir welding thin sheets (0.040") of aluminum alloys 2024 and 7075 are provided. The objective of this study was to investigate and document the effect of tool shoulder and pin diameter, as well as the presence of pin flutes, on the resultant microstructure and mechanical properties at both room temperature and cryogenic temperature. Specifically, the comparison between three tools will include: FSW process load analysis (tool forces required to fabricate the welds), Static Mechanical Properties (ultimate tensile strength, yield strength, and elongation), and Process window documenting the range of parameters that can be used with the three pin tools investigated. All samples were naturally aged for a period greater than 10 days. Prior research has shown 7075 may require post weld heat treatment. Therefore, an additional pair of room temperature and cryogenic temperature samples was post-weld aged to the 7075-T7 condition prior to mechanical testing.
The Mars Exploration Rovers (MER) Flight Software (FSW) is possibly the most complex software implmentation to be deployed on another planet. This paper provides an overview of the function and structure of the MER flight software.
The Mars Exploration Rovers (MER)Flight Software (FSW) was designed from the outset to be modified during operations. This paper discusses the content of the uplink products that are sent to the Rover, the planning of the Patch and Load activities, the testing of the products and prcedures, and the actual operations themselves.
A viewgraph presentation describing the effects of laser peening and shot peening on friction stir welding is shown. The topics include: 1) Background; 2) Friction Stir Welding (FSW); 3) Microstructure; 4) Laser & Shot Peening; 5) Residual Stresses; 6) Tensile Behavior; 7) Fatigue Life & Surface Roughness; 8) Crack Growth; and 9) Benefits.
An extended record of the Terra Surface and Atmosphere Radiation Budget (SARB) computed by CERES (Clouds and Earth s Radiant Energy System) is produced in gridded form, facilitating an investigation of global scale direct aerosol forcing. The new gridded version (dubbed FSW) has a spacing of 1 at the Equator. A companion document (Rutan et al. 2005) focuses on advances to (and validation of) the ungridded, footprint scale calculations (dubbed CRS), primarily in clear-sky conditions. While mainly intended to provide observations of fluxes at the top of atmosphere (TOA), CERES (Wielicki et al. 1996) includes a program to also compute the fluxes at TOA, within the atmosphere and at the surface, and also to validate the results with independent ground based measurements (Charlock and Alberta 1996). ARM surface data has been a focus for this component of CERES. To permit the user to infer cloud forcing and direct aerosol forcing with the computed SARB, CERES includes surface and TOA fluxes that have been computed for cloud-free (clear) and aerosol free (pristine) footprints; this accounts for aerosol effects (SW scattering and absorption, and LW scattering, absorption and emission) to both clear and cloudy skies.
The Orion Crew Exploration Vehicle (CEV) will be the first human spacecraft built by NASA in almost 3 decades and will be the first vehicle to perform both Low Earth Orbit (LEO) missions and lunar missions since Apollo. The awesome challenge of designing a Guidance, Navigation, and Control (GN&C) system for this vehicle that satisfies all of its various mission requirements is countered by the opportunity to take advantage of the improvements in algorithms, software, sensors, and other related GN&C technology over this period. This paper describes the CEV GN&C reference architecture developed to support the overall NASA reference configuration and validate the driving requirements of the Constellation (Cx) Architecture Requirements Document (CARD, Reference 1) and the CEV System Requirements Document (SRD, Reference 2). The Orion GN&C team designed the reference architecture based on the functional allocation of GN&C roles and responsibilities of CEV with respect to the other Cx vehicles, such as the Crew Launch Vehicle (CLV), Earth Departure Stage (EDS), and Lunar Surface Area Module (LSAM), across all flight phases. The specific challenges and responsibilities of the CEV GN&C system from launch pad to touchdown will be introduced along with an overview of the navigation sensor suite, its redundancy management, and flight software (FSW) architecture. Sensors will be discussed in terms of range of operation, data utility within the navigation system, and rationale for selection. The software architecture is illustrated via block diagrams, commensurate with the design aspects.
Friction plug welding (FPW) usage is advantageous for friction stir welding (FSW) hole close-outs and weld repairs in 2195 Al--Cu--Li fusion or friction stir welds. Current fusion welding methods of Al--Cu--Li have produced welds containing varied defects. These areas are found by non-destructive examination both after welding and after proof testing. Current techniques for repairing typically small (<0.25) defects weaken the weldment, rely heavily on welders' skill, and are costly. Friction plug welding repairs increase strength, ductility and resistance to cracking over initial weld quality, without requiring much time or operator skill. Friction plug welding while pulling the plug is advantageous because all hardware for performing the weld can be placed on one side of the workpiece.
The effects of laser, and shot peening on the fatigue life of Friction Stir Welds (FSW) have been investigated. The surface roughness resulting from various peening techniques was assessed, and the fracture surfaces microstructure was characterized. Laser peening resulted in an increase in fatigue life approximately 60%, while shot peening resulted in 10% increase when compared to the unpeened material. The surface roughness of shot peening was significantly higher compared to the base material, while specimens processed with laser peening were relatively smooth.
In this study, flat 0.250" thick Ti-6Al-4V panels were friction stir welded (FSWed) using weld tools with tapered pins. The five different pin geometries of the weld tools included: 0 degree (straight cylinder), 15 degree, 30 degree, 45 degree, and 60 degree angles on the frustum. All weld tools had a smooth 7 degree concave shoulder and were made from microwave sintered tungsten carbide. For each weld tool geometry, the FSW process parameters were optimized to eliminate internal defects. All the welds were produced in position control with a 2.5 degree lead angle using a butt joint configuration for the panels. The process parameters of spindle rpm and travel speed were varied, altering the hot working conditions imparted to the workpiece. Load cells on the FSWing machine allowed for the torque, the plunge force, and the plow force to be recorded during welding. Resulting mechanical properties were evaluated from tensile tests results of the FSWjoints. Variations in the material flow were investigated by use of microstructural analysis including optical microscopy (OM), scanning electron microscopy (SEM), and orientation image mapping (aIM).
This viewgraph presentation reviews the concept of the Operating System Abstraction Layer (OSAL) and its benefits. The OSAL is A small layer of software that allows programs to run on many different operating systems and hardware platforms It runs independent of the underlying OS & hardware and it is self-contained. The benefits of OSAL are that it removes dependencies from any one operating system, promotes portable, reusable flight software. It allows for Core Flight software (FSW) to be built for multiple processors and operating systems. The presentation discusses the functionality, the various OSAL releases, and describes the specifications.
This viewgraph presentation discusses the maintenance of flight software (FSW) on-orbit and the design of that software to allow maintenance of programs while they are on orbit.