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All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and Fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub element tests will be presented.

Shah, Sandeep↗
NASA NTRS1999

Aerospace Safety Advisory Panel

This report covers the activities of the Aerospace Safety Advisory Panel (ASAP) for calendar year 1998-a year of sharp contrasts and significant successes at NASA. The year opened with the announcement of large workforce cutbacks. The slip in the schedule for launching the International Space Station (ISS) created a five-month hiatus in Space Shuttle launches. This slack period ended with the successful and highly publicized launch of the STS-95 mission. As the year closed, ISS assembly began with the successful orbiting and joining of the Functional Cargo Block (FGB), Zarya, from Russia and the Unity Node from the United States. Throughout the year, the Panel maintained its scrutiny of NASA's safety processes. Of particular interest were the potential effects on safety of workforce reductions and the continued transition of functions to the Space Flight Operations Contractor. Attention was also given to the risk management plans of the Aero-Space Technology programs, including the X-33, X-34, and X-38. Overall, the Panel concluded that safety is well served for the present. The picture is not as clear for the future. Cutbacks have limited the depth of talent available. In many cases, technical specialties are 'one deep.' The extended hiring freeze has resulted in an older workforce that will inevitably suffer significant departures from retirements in the near future. The resulting 'brain drain' could represent a future safety risk unless appropriate succession planning is started expeditiously. This and other topics are covered in the section addressing workforce. The major NASA programs are also limited in their ability to plan property for the future. This is of particular concern for the Space Shuttle and ISS because these programs are scheduled to operate well into the next century. In the case of the Space Shuttle, beneficial and mandatory safety and operational upgrades are being delayed because of a lack of sufficient present funding. Likewise, the ISS has little flexibility to begin long lead-time items for upgrades or contingency planning. For example, the section on computer hardware and software contains specific findings related to required longer range safety-related actions. NASA can be proud of its accomplishments this past year, but must remain ever vigilant, particularly as ISS assembly begins to accelerate. The Panel will continue to focus on both the short- and long-term aspects of risk management and safety planning. This task continues to be made manageable and productive by the excellent cooperation the Panel receives from both NASA and its contractors. Particular emphasis will continue to be directed to longer term workforce and program planning issues as well as the immediate risks associated with ISS assembly and the initial flights of the X-33 and X-34. Section 2 of this report presents specific findings and recommendations generated by ASAP activities during 1998. Section 3 contains more detailed information in support of these findings and recommendations. Appendix A is a current roster of Panel members, consultants, and staff. Appendix B contains NASA's response to the findings and recommendations from the 1997 ASAP Annual Report. Appendix C details the fact-finding activities of the Panel in 1998. During the year, Mr. Richard D. Blomberg was elected chair of the Panel and Vice Admiral (VADM) Robert F Dunn was elected deputy chair. VADM Bernard M. Kauderer moved from consultant to member. Mr. Charles J. Donlan retired from the Panel after many years of meritorious service. Ms. Shirley C. McCarty and Mr. Robert L. ('Hoot') Gibson joined the Panel as consultants.

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NASA NTRS2001

Challenges and Opportunities in Design, Fabrication, and Testing of High Temperature Joints in Ceramics and Ceramic Composites

Ceramic joining has been recognized as an enabling technology for successful utilization of advanced ceramics and composite materials. A number of joint design and testing issues have been discussed for ceramic joints in silicon carbide-based ceramics and fiber-reinforced composites. These joints have been fabricated using an affordable, robust ceramic joining technology (ARCJoinT). The microstructure and good high temperature mechanical capability (compressive and flexural strengths) of ceramic joints in silicon carbide-based ceramics and composite materials are reported.

Singh, M.↗
NASA NTRS2001

Friction Stir Welding of Steel Alloys

The friction stir welding process has been developed primarily for the welding of aluminum alloys. Other higher melting allows such, as steels are much more difficult to join. Special attention must be given to pin tool material selection and welding techniques. This paper addresses the joining of steels and other high melting point materials using the friction stir welding process. Pin tool material and welding parameters will be presented. Mechanical properties of weldments will also be presented. Significance: There are many applications for the friction stir welding process other than low melting aluminum alloys. The FSW process can be expanded for use with high melting alloys in the pressure vessel, railroad and ship building industries.

Ding, R. Jeffrey↗
NASA NTRS2001

Orbital Friction Stir Weld System

This invention is an apparatus for joining the ends of two cylindrical (i.e., pipe-shaped) sections together with a friction stir weld. The apparatus holds the two cylindrical sections together and provides back-side weld support as it makes a friction stir weld around the circumference of the joined ends.

R Jeffrey Ding↗
NASA NTRS2001

Passive Capture Joint with Three Degrees of Freedom

A passive capture joint with three degrees of freedom is presented wherein two structural elements are joined together solely by moving the two elements into position, and which when joined together have rotation in all three axes. The inventive apparatus is comprised of two halves: (1) a joint ball mounted on a stem as in a common trailer hitch, and; (2) a socket. The socket consists of a base having an exterior wall and forming an interior chamber, the chamber having a top end and a bottom end, and an interior wall. The chamber is open at the top end, and forms a spherical cup at the bottom end. The socket base's interior chamber is sized to accept the joint ball. The base also forms at least one bore at an acute angle away from the interior chamber's open end. The bores have a first opening in the interior wall of the chamber, and a second opening in the exterior wall of the base. Retaining balls sized to fit within the bores, but to only partially pass through the first opening, are moveably housed within the bores. The retaining balls are moveably held in the first opening by a compression spring housed in the bore. As the joint ball is inserted in the chamber it forces the retaining balls back into the bore until the equator of the joint ball passes. Because the bore is at an acute angle to the chamber the joint ball cannot exit the chamber without the joint being unlocked. The joint is unlocked by rotating a locking ring which encircles the base and covers the second opening. The locking ring has a radial slot for each retaining ball, disposed angularly from the base, and sized to allow passage of the retaining ball in the radial direction when the locking ring is rotated to align the radial slot with the second opening.

Richard A Cloyd↗
NASA NTRS2002

Friction-Stir Welding of Aluminum For the Space Program

The Marshall Space Flight Center is developing and characterizing the friction stir welding process for the Space Shuttle and other space programs. This revolutionary process, invented and patented by The Weld Institute in England, offers tremendous advantages for joining aluminum for high performance applications. It is particularly suited for advanced aluminum-lithium alloys, such as 2195, the primary structural alloy used in the External Tank. The friction stir welding process joins metals with minimal heat input, resulting in high-strength joints with high ductility. It is a simple process to demonstrate using a common milling machine for sample parts, but relatively expensive to implement on large-scale hardware, due to the high cost of tooling needed to handle the high forging pressures characteristic of the process. Recent developments at the Marshall Space Flight Center have demonstrated friction stir welding on linear joints up to 5 meters (15 ft.), with material thickness ranging between 2.5 mm and 16.5 mm (0.100" to 0.650"). High efficiency weld joints have been produced in aluminum from the 2000, 5000, and 6000 series alloy systems. A "retractable pin tool" system was patented by MSFC that allows use of friction stir welding for joints with changing material thickness, and with less rigid tooling than previously considered. This presentation will describe the details of alloys welded to-date and technical advances under development at MSFC. These developments could have substantial benefit to industrial applications for welding aluminum.

Jones, Clyde S.↗
NASA NTRS2002

Structural Assembly Device

A structural assembly device and method for securing together a pair of surfaces of two fusible materials wherein an electrically conductive thermal element is located between the surfaces which will melt, without substantially degrading, when heated. When the thermal element is heated, it is elevated to a temperature sufficient to melt the first and second elements and then is allowed to cool such that the first and second elements are joined to the thermal element and may be joined to each other as well.

Melvin A Bryant, III↗
NASA NTRS1996

Advanced Welding Torch

In order to more easily join the huge sections of the Space Shuttle external tank, Marshall Space Flight Center initiated development of the existing concept of Variable Polarity Plasma Arc (VPPA) welding. VPPA welding employs a variable current waveform that allows the system to operate for preset time increments in either of two polarity modes for effective joining of light alloys. Marshall awarded the torch contract to B & B Precision Machine, which produced a torch for the Shuttle, then automated the system, and eventually delivered a small torch used by companies such as Whirlpool for sheet metal welding of appliance parts and other applications. The dependability of the torch offers cost and time advantages.

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NASA NTRS1991

Induction Heating Systems

Induction heating technology, a magnetic non-deforming process, was developed by Langley researchers to join plastic and composite components in space. Under NASA license, Inductron Corporation uses the process to produce induction heating systems and equipment for numerous applications. The Torobonder, a portable system, comes with a number of interchangeable heads for aircraft repair. Other developments are the E Heating Head, the Toroid Joining Gun, and the Torobrazer. These products perform bonding applications more quickly, safely and efficiently than previous methods.

Source record↗
NASA NTRS1984

Portable Welder

A low cost, low power, self-contained portable welding gun designed for joining thermoplastics which become soft when heated and harden when cooled was developed originally by NASA's Langley Research Center for repairing helicopter windshields. Welder has a broad range of applications for joining both thermoplastic materials in the aerospace, automotive, appliance, and construction industries. Welders portability and low power requirement allow its use on-site in any type of climate, with power supplied by a variety of portable sources.

Source record↗
NASA NTRS2002

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary toolless pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗
NASA NTRS1982

Advanced Welding Tool

Accutron Tool & Instrument Co.'s welder was originally developed as a tool specifically for joining parts made of plastic or composite materials in any atmosphere to include the airless environment of space. Developers decided on induction or magnetic heating to avoid causing deformation and it also can be used with almost any type of thermoplastic material. Induction coil transfers magnetic flux through the plastic to a metal screen that is sandwiched between the sheets of plastic to be joined. When welder is energized, alternating current produces inductive heating on the screen causing the adjacent plastic surfaces to melt and flow into the mesh, creating a bond on the total surface area. Dave Brown, owner of Great Falls Canoe and Kayak Repair, Vienna, VA, uses a special repair technique based on operation of the Induction Toroid Welder to fix canoes. Whitewater canoeing poses the problem of frequent gashes that are difficult to repair. The main reason is that many canoes are made of plastics. The commercial Induction model is a self-contained, portable welding gun with a switch on the handle to regulate the temperature of the plastic melting screen. Welder has a broad range of applications in the automobile, appliance, aerospace and construction industries.

Source record↗
NASA NTRS2003

Flaw Tolerance in Lap Shear Brazed Joints

Furnace brazing is a joining process used in the aerospace and other industries to produce strong permanent and hermetic structural joints. As in any joining process, brazed joints have various imperfections and defects. At the present time, our understanding of the influence of the internal defects on the strength of the brazed joints is not adequate. The goal of this 3-part investigation is to better understand the properties and failure mechanisms of the brazed joints containing defects. This study focuses on the behavior of the brazed lap shear joints because of their importance in manufacturing aerospace structures. In Part 1, an average shear strength capability and failure modes of the single lap joints are explored. Stainless steel specimens brazed with pure silver are tested in accordance with the AWS C3.2 standard. Comparison of the failure loads and the ultimate shear strength with the Finite Element Analysis (FEA) of the same specimens as a function of the overlap widths shows excellent correlation between the experimental and calculated values for the defect-free lap joints. A damage zone criterion is shown to work quite well in understanding the failure of the braze joints. In Part 2, the findings of the Part 1 will be verified on the larger test specimens. Also, various flaws will be introduced in the test specimens to simulate lack of braze coverage in the lap joints. Mechanical testing and FEA will be performed on these joints to verify that behavior of the flawed ductile lap joints is similar to joints with a reduced braze area. Finally, in Part 3, the results obtained in Parts 1 and 2 will be applied to the actual brazed structure to evaluate the load-carrying capability of a structural lap joint containing discontinuities. In addition, a simplified engineering procedure will be offered for the laboratory testing of the lap shear specimens.

Flom, Yury↗
NASA NTRS2002

Distributed Framework for Dynamic Telescope and Instrument Control

Traditionally, instrument command and control systems have been developed specifically for a single instrument. Such solutions are frequently expensive and are inflexible to support the next instrument development effort. NASA Goddard Space Flight Center is developing an extensible framework, known as Instrument Remote Control (IRC) that applies to any kind of instrument that can be controlled by a computer. IRC combines the platform independent processing capabilities of Java with the power of the Extensible Markup Language (XML). A key aspect of the architecture is software that is driven by an instrument description, written using the Instrument Markup Language (IML). IML is an XML dialect used to describe graphical user interfaces to control and monitor the instrument, command sets and command formats, data streams, communication mechanisms, and data processing algorithms. The IRC framework provides the ability to communicate to components anywhere on a network using the JXTA protocol for dynamic discovery of distributed components. JXTA (see httD://www.jxta.org,) is a generalized protocol that allows any devices connected by a network to communicate in a peer-to-peer manner. IRC uses JXTA to advertise a device's IML and discover devices of interest on the network. Devices can join or leave the network and thus join or leave the instrument control environment of IRC. Currently, several astronomical instruments are working with the IRC development team to develop custom components for IRC to control their instruments. These instruments include: High resolution Airborne Wideband Camera (HAWC), a first light instrument for the Stratospheric Observatory for Infrared Astronomy (SOFIA); Submillimeter And Far Infrared Experiment (SAFIRE), a Principal Investigator instrument for SOFIA; and Fabry-Perot Interferometer Bolometer Research Experiment (FIBRE), a prototype of the SAFIRE instrument, used at the Caltech Submillimeter Observatory (CSO). Most recently, we have been working with the Submillimetre High Angular Resolution Camera IInd Generation (SHARCII) at the CSO to investigate using IRC capabilities with the SHARC instrument.

Ames, Troy J.↗
NASA NTRS2003

Intercomparison of Atmospheric Radiation Schemes for the Lower Martian Atmosphere

Interpretation of the vast data flow from the recent and ongoing Mars missions requires extensive modeling activity to support the investigations and conclusions drawn from the observations. We have initiated a campaign to compare atmospheric radiation schemes for the lower Martian atmosphere with leastcompromise reference line-by-line calculations (Meadows and Crisp 1996, Crisp 1986). By using fixed reference conditions we are introducing an intercomparison framework to enable atmospheric modeling teams to compare their modeling results with the reference line-by-line calculations, and to improve their models. The atmosphere of Mars is thin and therefore its response to local radiative forcing is strong when compared to that of the Earth s troposphere. Airborne dust and also the water vapor give significant contributions to the radiative fluxes. Thus models of the Martian atmosphere should have fairly accurate radiative transfer (RT) algorithms. This is specifically important for the net radiative flux at the surface, which is the main driver for the surface temperature evolution, since the surface turbulent fluxes are small due to the thin atmosphere (e.g. Haberle et al. 1993, Savij arvi 1991a, Savij arvi 1991b, Savij arvi 1999). However, the accuracy of the RT schemes has not been rigorously tested in many cases as reference calculations have been rare. We introduce a set of reference cases for Martian atmospheric conditions with profiles for temperature, pressure, dust optical depth (Conrath 1975, Clancy et al. 1995, OckertBell et al. 1997, Smith et al. 2000), water, CO2,O3,CO and O2 (Table 1). The reference atmosphere uses a diurnally and globally averaged thermal structure derived from Mariner 9 IRIS observations acquired during late southern summer. Thermal structures for nighttime and daytime conditions will be included shortly. Computationally expensive reference simulations were performed by applying a spectrum resolving (line-by-line multiple scattering) model, SRM, to give the least-compromise base for comparisons. We call for other groups to join in future comparisons. This resembles the International Comparison of Radiation Codes for Climate Models (ICRCCM; e.g. Ellingson and Fouquart 1991, Ellingson et al. 1991). The ICRCCM led to many improvements in the Earth GCM radiation codes. The intercomparison framework presented in this paper is a step toward that direction for Mars. We have already five modeling teams participating in this intercomparison exercice. Additional teams investigating the Martian atmosphere are cordially invited to join this effort of comparing the radiation schemes in fixed conditions. The results achieved will be reported and some additional features to be included in the intercomparison will be discussed.

A-M Harri↗
NASA NTRS2003

Thermo-Mechanical Processing in Friction Stir Welds

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.

Schneider, Judy↗
NASA NTRS2003

Isothermal Calorimetric Observations of the Effect of Welding on Compatibility of Stainless Steels with High-Test Hydrogen Peroxide Propellant

High-Test Hydrogen Peroxide (HTP) is receiving renewed interest as a monopropellant and as the oxidizer for bipropellant systems. HTP is hydrogen peroxide having concentrations ranging from 70 to 98%. In these applications the energy and oxygen released during decomposition of HTP is used for propulsion. In propulsion systems components must be fabricated and connected using available joining processes. Welding is a common joining method for metallic components. The goal of this study was to compare the HTP compatibility of welded vs. unwelded stainless steel.

Gostowski, Rudy↗