SEARCH · Search NASA
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Programming artifice keeps weld puddle from running off. Dummy points added during off-line programming of circular, noncontiguous computer-controlled weld path to keep weld puddle in proper orientation at ends of path. Incorporation of dummy points simple and requires only few extra minutes of programming effort.
Fusion welding for thermoplastic composite wind turbine blades is being investigated as a replacement for adhesives in bond lines to reduce manufacturing time and cost and to promote ease of recyclability. Resistance welding uses an electrically conductive material, such as carbon fiber, embedded in the bond line to heat the joining surfaces and fuse them together under pressure. One main challenge with fusion joining for large wind blades is the ability to use this conductive heating element in the bond line while still protecting the blade from the catastrophic effects of a lightning strike. This paper outlines the design and manufacturing of a lightning protection system for a 5-m-long thermally welded blade tip. The outcomes of high voltage and high current lightning testing applied to the 5 m blade tip show that the proposed design was able to protect the fusion welded bond lines from significant lightning damage.
Proposed hardware and software for microprocessor-controlled power supplies and welding machines are described. The application of the automatic seven-axis welding machine, which is to be preprogrammed to allow minimum intervention by the welding operator during the actual process, to the welding of the Space Shuttle main engine is discussed. The production requirements for the gas tungsten arc welds for the Space Shuttle main engine are examined. Consideration is given to positioner design, welding variables, inert shielding gas management, filler metal wire control, the up loading and down loading of data from off-line computers, process improvements, tooling, the welding variable library, and adaptive sensor control.
Special ultrasonic search unit, or transducer assembly, reliably inspects the quality of melt-through welds of fusion welded tubing couplers for hydraulic lines. This instrumentation can also be used to detect faulty braze bonds in thin-walled, small diameter joints and wall thickness of thin-walled metal tubing.
This paper describes the use of computer graphic simulation techniques to resolve critical design and operational issues for robotic systems. Use of this technology will result in greatly improved systems and reduced development costs. The major design issues in developing effective robotic systems are discussed and the use of ROBOSIM, a NASA developed simulation tool, to address these issues is presented. Three representative simulation case studies are reviewed: off-line programming of the robotic welding development cell for the Space Shuttle Main Engine (SSME); the integration of a sensor to control the robot used for removing the Thermal Protection System (TPS) from the Solid Rocket Booster (SRB); and the development of a teleoperator/robot mechanism for the Orbital Maneuvering Vehicle (OMV).
This paper describes the use of computer graphic simulation techniques to resolve critical design and operational issues for robotic systems. Use of this technology will result in greatly improved systems and reduced development costs. The major design issues in developing effective robotic systems are discussed and the use of ROBOSIM, a NASA developed simulation tool, to address these issues is presented. Three representative simulation case studies are reviewed: off-line programming of the robotic welding development cell for the Space Shuttle Main Engine (SSME); the integration of a sensor to control the robot used for removing the Thermal Protection System (TPS) from the Solid Rocket Booster (SRB); and the development of a teleoperator/robot mechanism for the Orbital Maneuvering Vehicle (OMV).
The use of computer graphic simulation techniques to resolve critical design and operational issues for robotic systems is described. Use of this technology will result in greatly improved systems and reduced development costs. The major design issues in developing effective robotic systems are discussed and the use of ROBOSIM, a NASA developed simulation tool, to address these issues is presented. Three representative simulation case studies are reviewed: off-line programming of the robotic welding development cell for the Space Shuttle Main Engine; the integration of a sensor to control the robot used for removing the Thermal Protection System from the Solid Rocket Booster; and the development of a teleoperator/robot mechanism for the Orbital Maneuvering Vehicle.
A press conference held on December 16, 1999, to explain the reason behind NASA's decision to delay the Discovery's launching by a period of 24 hrs is presented. According to Ron Dittemore, Space Shuttle Program Manager, the STS-103 team delayed the launch because they need extra time to check one vendor's manufacturing processes, after an x-ray inspection revealed that an improper weld rod was used to weld one of the pressuring lines (called NPS lines) in the ET (external tank). Mr. Dittemore explained that since it is in the ET (not a major load carrying structure and rebuild after each flight), it did not pose any danger to the STS-103 flight. However, the same vendor also manufactured some parts of the orbiter and the team wanted to make sure that the quality of the vendor's manufacturing processes is robust before launching the orbiter to space. He also answered some reporters' questions.
Propulsion systems that utilize hypergolic propellants have been used to power space vehicles since the beginning of the space program. Liquid methane and oxygen propulsion systems have emerged as an alternative and have proven to be more environmentally friendly. The incorporation of liquid methane/liquid oxygen (LOX) into the propulsion system has demonstrated an increase in engine performance, as well as a reduction in the volume, size and complexity of the system. Consequently, reducing the total mass of the vehicle which is a crucial aspect that is considered when planning space missions to both the Moon and Mars [1]. Project Morpheus has made significant advancements in liquid oxygen/liquid methane propulsion system technologies by incorporating a LOX/methane propulsion system to a vertical test bed. The vehicle consisted of a 5,000 lb main engine and four 20 lb remote control system (RCS) engines that utilize liquid methane/LOX as its propellant [1]. The vehicle completed successful flight testing at Kennedy Space Center in 2014 which marked the completion of the Morpheus project. Subsequent projects utilizing Morpheus' vertical test bed have been developed to make further advancements. One of the subsequent projects consisted of the addition of a smaller 2,000 lb main engine and a cold helium heat exchanger which would make it possible for a pressurant tank systems to be send to Mars or the Moon by significantly decreasing the overall mass and volume of the pressurant tank. The hot fire tests of the integrated system with the smaller main engine and cold helium heat exchanger were successful at sea level, but further studies are being conducted to better understand how the vertical test bed will behave under thermal-vacuum conditions. For this reason, the integrated vehicle will be taken to Plum Brook to be tested in a chamber capable of simulating these conditions. To ensure that the vehicle will function properly under vacuum conditions, testing will be first completed at the component level. During this process, the igniter of the main engine and the RCS thrusters will be tested under a vacuum. To complete the testing of the components, the test setup first needed to be finalized. The CryoCart is being used to feed the propellants to the test article. The CryoCart is a movable test set-up that was developed in 2009 to provide a mobile platform for testing oxygen/methane systems with hot-fire capability up to 100 lbf. The CryoCart consists of three different systems: Oxygen, Methane, and liquid Nitrogen. The Oxygen and Methane systems are placed into two different carts while the liquid nitrogen system is mainly located in the methane cart. Over the years, the CryoCart has been utilized for different projects and has undergone deterioration. For this reason, a new phase has been developed to rebuild it to working conditions once again. During my internship, I was aiding in the construction and restoration of the CryoCart. In the initial stages of the process, I updated the fluid and electrical schematics for the oxygen, methane, and test article systems. The original CryoCart consisted of an electrical panel that utilized electromechanical relays and a terminal to drive the igniter power and signal, as well as the main fuel and oxygen valves. This electrical panel connected to the CryoCart through various wire harnesses that could be found exiting from the CryoCart. First, it was determined how these harnesses connected to the electromechanical relays so that they worked correctly. Once the electrical system was understood, an alternative for the electromechanical relays and the Molex connectors used throughout the system was sought since these components can often prove to be unreliable. Solid State relays and MIL connectors were purchased to serve as replacements. Upon arrival of the parts, crimping and wiring was completed to install the new solid state relays and MIL connectors. During the replacement of the relays and connectors, system checks of the electrical system were ran to ensure that the system was working correctly. While completing system checks, the pressure transducers that were not functioning properly were also replaced and any issue with the wiring or signal was addressed. Once the electrical components were replaced, the restoration of the fluid system began. Parts of the tubing in the CryoCart had to be rebuild and often consisted of sizing, cutting, bending, filing, and sanding the tubing to prepare it to be flared. Many components had to be proof-tested to bring their certifications up to date, and several components had to be replaced. Various flex hoses, valves, and fittings were send to the Clean Lab because they were new, dirty, or had gone through proof-testing. Once they arrived from the cleaning lab they had to be put back to the system and leak checks and functional tests were conducted. In the Nitrogen system, the copper tubing located in the Oxygen cart was rebuild and Aerogel insulation was added to this section. A new gaseous nitrogen system was added to the CryoCart to purge the vacuum tube which will serve as the test chamber. Once the CryoCart was completed, construction of parts of the vacuum tube began. A flange was manufactured with welded fittings to hold the line of the vacuum pump as well as some extra fittings which will serve as extra inlets used to introduce fluid lines to the vacuum tube. Stress analysis was ran in this flange to ensure that it would not fail under vacuum conditions. The fluid lines leading from the air side of the vacuum to the test article were also constructed and added to the mount that had already been manufactured. Three different sets of tubing were constructed to accommodate the seven different RCS thruster and the main engine igniter that are going to be tested. Full electrical system checks were completed to ensure that all the wire harnesses and valves were functioning. Upon the completion of the CryoCart and the vacuum tube, hot fire testing for the RCS thrusters and the main engine igniter are going to begin. During this time any issues encountered with the engines or igniter will be addressed to ensure that the components function under vacuum conditions. After successful completion of testing, the vertical test bed, Morpheus, will be rebuilt and prepared to be sent to Plum Brook. In Plum Brook, the vehicle will be tested in the thermal-vacuum chamber to demonstrate that integrated lox-methane propulsion system operation in space-like conditions. This internship has allowed me the opportunity to gain valuable hands on experience and to develop skills that will aid in my education as well as in the workforce, while at the same time helping me determine that I would like to further pursue a career in propulsion engineering.
In support of the reactor-vessel development effort of SHINE medical technologies, irradiation of its structural materials and post-irradiation testing have been performed in the High Flux Isotope Reactor at Oak Ridge National Laboratory. This irradiation was performed on welded and unwelded AISI 347 steel and Zircaloy-4 samples at low temperature (~60°C) in contact with the reactor coolant. Hardness, Charpy, and tensile data have been taken from all cases of unirradiated specimens, while post-irradiation tensile and hardness data have been taken from AISI 347 base metal and Zircaloy-4 base metal and weld specimens so far. Additionally, 3-point bend data have been taken from explosion-welded specimens. The expected changes to hardness, yield strength, ultimate tensile strength, uniform elongation, and total elongation as a result of the low temperature and low dose neutron irradiation are reported here.
SHINE Medical Technologies is developing a facility that will produce molybdenum-99 for medical isotope procedures. As part of this facility, a metal tank, called the target solution vessel (TSV), will hold a uranyl sulfite solution. The TSV must withstand neutron irradiation near room temperature and potential corrosion from the aqueous solution. The large cylindrical TSV will be fabricated by welding and will have numerous pipes and connections also attached via welding. The vessel and those pipes will have varying thicknesses so both gas tungsten arc welding (GTAW) and flux-cored arc welding (FCAW) will be necessary to fabricate different sections. The original material under consideration for the TSV was Zircaloy-4 (Zry-4), but it is known to form a hydride which can degrade its mechanical properties. Thus, some investigation here is focused on the effects of hydrogen uptake in the Zry-4. Additionally, the alternative material being considered is AISI 347, a stainless steel. Both materials have little existing data for their neutron irradiation behavior below 100°C, and both have open questions on the weld behavior under neutron irradiation. Testing has focused on characterizing their weld properties with tensile tests and performing neutron irradiation of samples in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL).
Solid-state welding processes were evaluated for joining TD-NiCrAl (Ni-16Cr-4Al-2ThO2) alloy sheet. Both hot-press and resistance spot welding techniques were successfully applied in terms of achieving grain growth across the bond line. Less success was achieved with a resistance seam welding process. In stress-rupture shear and tensile shear tests of lap joints at 1100 C, most failures occurred in the parent material, which indicates that the weld quality was good and that the welds were not a plane of weakness. The overall weld quality was not as good as previously attained with TD-NiCr, probably because the presence of alumina at the faying surfaces and the developmental TD-NiCrAl sheet, which was not of the quality of the TD-NiCr sheet in terms of surface flatness and dimensional control.
Strains at twenty-one selected points in the critical lower weld region of a aft skirt of a solid rocket booster of the shuttle were measured using photoelastic coatings and stress separator gages. Data were taken at loads of 5, 14, 20, 28, 42, 56, and 70 percent of the design limit load. Results indicate that general yielding occurred in the weld metal and for a short distance outside the fusion boundaries on either side of the weld metal. The fusion boundaries did not yield at the 70 percent load. Slight non-linearity in the load strain curves were observed at several points above the 20 percent load level. Maximum measured strains occurred at points in the forged metal of the holddown post along a line 0.50 inches from the centerline of the weld. Maximum shearing strains within the area covered by the photoelastic coating occurred at points approximately 0.33 inches to the right of the weld centerline near points 6 and 7 and lying along a yellow vertical line extending from just below point 6 to point 11. Photoelastic coatings were shown to be an excellent method to provide the whole field strain distribution in the region of the critical weld and to enhance the overall understanding of the behavior of the welded joint.
Technique uses a stiff medium in the annular space between inner and outer pipes of jacketed piping in transfer lines. The process eliminates splitting and welding and makes possible the use of standard pipe-bending tools.
During the manufacture of space-based assemblies such as Space Shuttle Main Engines, flexibility is required due to the high-cost and low-volume nature of the end products. Various systems have been developed pursuing the goal of adaptive, flexible manufacturing for several space applications, including an Advanced Robotic Welding System for the manufacture of complex components of the Space Shuttle Main Engines. The Advanced Robotic Welding System (AROWS) is an on-going joint effort, funded by NASA, between NASA/Marshall Space Flight Center, and two divisions of Rockwell International: Rocketdyne and the Science Center. AROWS includes two levels of flexible control of both motion and process parameters: Off-line programming using both geometric and weld-process data bases, and real-time control incorporating multiple sensors during weld execution. Both control systems were implemented using conventional hardware and software architectures. The feasibility of enhancing the real-time control system using the problem-solving architecture of Schemer is investigated and described.
Computer simulations, robotic inspections, and visual inspections performed to detect discrepancies. Method for verification of tooling for robotic welding involves combination of computer simulations and visual inspections. Verification process ensures accuracy of mathematical model representing tooling in off-line programming system that numerically simulates operation of robotic welding system. Process helps prevent damaging collisions between welding equipment and workpiece, ensures tooling positioned and oriented properly with respect to workpiece, and/or determines whether tooling to be modified or adjusted to achieve foregoing objectives.
This paper reviews the MDA independent research and development (IRAD) efforts since 1986 in the development of two distinctly different approaches to on-orbit tube repair: (1) one-piece mechanical tube fittings that are forced, under pressure, onto the tube outer surface to effect the repair; and (2) electron beam weldings as demonstrated with the Paton-developed universal hand tool (UHT) space welding system for the repair of fluid lines and tubular components. Other areas of potential on-orbit repair using the UHT include damage to the flat or curved surfaces of habitation modules and truss assemblies. This paper will also address MDA evaluation of the Paton UHT system for on-orbit coating, cleaning, brazing, and cutting of metals. MDA development of an on-orbit compatible nondestructive evaluation (NDE) system for the inspection of tube welds is an important part of this complete space welding capability and will be discussed in a separate paper.
Metal Y-tube simultaneously directs argon streams over weld areas on both sides of tubes being joined along a line on their outer periphery. The device is advanced along the junction in step with the welding operation.