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NASA NTRS1987

Advanced radiator concepts utilizing honeycomb panel heat pipes

The feasibility of fabricating and processing moderate temperature range vapor chamber type heat pipes in a low mass honeycomb panel configuration for highly efficient radiator fins for potential use on the space station was investigated. A variety of honeycomb panel facesheet and core-ribbon wick concepts were evaluated within constraints dictated by existing manufacturing technology and equipment. Concepts evaluated include type of material, material and panel thickness, wick type and manufacturability, liquid and vapor communication among honeycomb cells, and liquid flow return from condenser to evaporator facesheet areas. A thin-wall all-welded stainless steel design with methanol as the working fluid was the initial prototype unit. It was found that an aluminum panel could not be fabricated in the same manner as a stainless steel panel due to diffusion bonding and resistance welding considerations. Therefore, a formed and welded design was developed. The prototype consists of ten panels welded together into a large panel 122 by 24 by 0.15 in., with a heat rejection capability of 1000 watts and a fin efficiency of essentially 1.0.

Fleischman, G. L.↗

NASA NTRS1983

Practical small-scale explosive seam welding

A small-scale explosive seam welding process has been developed that can significantly contribute to remote metal joining operations under hazardous or inaccessible conditions, such as nuclear reactor repair and assembly of structure in space. This paper describes this explosive seam welding process in terms of joining principles, variables, types of joints created, capabilities, and applications. Very small quantities of explosive in a ribbon configuration are used to create narrow (less than 0.5 inch), long-length, uniform, hermetically sealed joints that exhibit parent metal properties in a wide variety of metals, alloys, and combinations. The practicality of this process has been demonstrated by its current acceptance, as well as its capabilities that are superior in many applications to the universally accepted joining processes, such as mechanical fasteners, fusion and resistance welding, and adhesives.

Bement, L. J.↗

NASA NTRS1983

Practical small-scale explosive seam welding

Bement, L. J.↗

NASA NTRS1977

Elevated-temperature flow strength, creep resistance and diffusion welding characteristics of Ti-gAl-2Nb-1Ta-0.8Mo

A study of the flow strength, creep resistance and diffusion welding characteristics of the titanium alloy Ti-6Al-2Nb-1Ta-0.8Mo was conducted. Two mill-processed forms of this alloy were examined. The forged material was essentially processed above the beta transus while the rolled form was subjected to considerable work below the beta transus. Between 1150 and 1250 K, the forged material was stronger and more creep resistant than the rolled alloy. Both forms exhibit superplastic characteristics in this temperature range. Strain measurements during diffusion welding experiments at 1200 K reveal that weld interfaces have no measurable effect on the overall creep deformation. Significant deformation appears to be necessary to produce a quality diffusion weld between superplastic materials. A 'soft' interlayer inserted between faying surfaces would seemingly allow manufacture of quality diffusion welds with little overall deformation.

Whittenberger, J. D.↗

NASA NTRS1979

Elevated temperature flow strength, creep resistance and diffusion welding characteristics of Ti-6Al-2Nb-1Ta-0.8Mo

A study of the flow strength, creep resistance and diffusion welding characteristics of the titanium alloy Ti-6Al-2Nb-1Ta-0.8Mo has been conducted. Two mill-processed forms of this alloy were examined. The forged material had been processed above the beta transus (approximately 1275 K) while the rolled form had been subjected to work below the beta transus. Between 1150 and 1250 K, the forged material was stronger and more creep resistant than the rolled alloy. Both forms exhibit superplastic characteristics in this temperature range. Strain measurements during diffusion welding experiments at 1200 K reveal that weld interfaces have no measurable effect on the overall creep deformation. Significant deformation appears to be necessary to produce a quality diffusion weld between superplastic materials. A 'soft' interlayer inserted between faying surfaces would seemingly allow manufacture of quality diffusion welds with little overall deformation.

Whittenberger, J. D.↗

NASA NTRS1968

Welder analyzer

Welder analyzer circuit evaluates and certifies resistance welding machines. The analyzer measures peak current, peak voltage, peak power, total energy, and first-pulse energy. It is used as an energy monitor while welding is being performed, or a precision shunt load for a pure electrical evaluation of the weld machine.

Miller, L. L.↗

NASA NTRS1972

FCC in Viking articulated boom

The application requirements and manufacturing techniques for the flat conductor cable used in the Viking Lander Articulated Boom Unit are described. The Viking Boom is a 3-axis device utilized to position a soil sampler and provide digging forces. This application imposed severe restrictions on size, weight, materials, and choice of manufacturing processes. The final cable assembly design resulted in a combination of collated cable and flexible circuits assembled by resistance welding techniques.

Hawkins, E. S.↗

NASA NTRS1973

Development of a lightweight body-mounted solar cell array with a high power to weight ratio.

Three lightweight solar cell arrays have been fabricated with a high power-to-weight ratio. These arrays incorporate resistance welded interconnections, improved antireflection coating on the solar cell and lightweight substrates. Two of the substrates were constructed of magnesium with different structural geometry, while the third substrate was conventional aluminum honeycomb. All arrays utilized thin solar cells having a titanium-palladium-silver contact system and an antireflection coating of titanium oxide. The cells were welded with silver plated molybdenum interconnections. The two arrays having magnesium substrates exhibited a power/weight of 70.4 W/kg (32 W/lb.) and 81 W/kg (36.8 W/lb.), while the conventional array demonstrated a power/weight of 45.2 W/kg (20.6 W/lb.).

Somberg, H.↗

NASA NTRS1976

Flexible, FEP-Teflon covered solar cell module development

Techniques and equipment were developed for the large scale, low-cost fabrication of lightweight, roll-up and fold-up, FEP-Teflon encapsulated solar cell modules. Modules were fabricated by interconnecting solderless single-crystal silicon solar cells and heat laminating them at approximately 300 C between layers of optically clear FEP and to a loadbearing Kapton substrate sheet. Modules were fabricated from both conventional and wraparound contact solar cells. A heat seal technique was developed for mechanically interconnecting modules into an array. The electrical interconnections for both roll-up and fold-up arrays were also developed. The use of parallel-gap resistance welding, ultrasonic bonding, and thermocompression bonding processes for attaching interconnects to solar cells were investigated. Parallel-gap welding was found to be best suited for interconnecting the solderless solar cells into modules. Details of the fabrication equipment, fabrication processes, module and interconnect designs, environmental test equipment, and test results are presented.

Rauschenbach, H. S.↗

NASA NTRS1977

Low thermal flux glass-fiber tubing for cryogenic service

This paper describes analytical techniques, fabrication development, and test results for composite tubing that has many applications in aerospace and commercial cryogenic installations. Metal liner fabrication is discussed in detail with attention given to resistance-welded liners, fusion-welded liners, chem-milled tubing liners, joining tube liners and end fittings, heat treatment and leak checks. Composite overwrapping, a second method of tubing fabrication, is also discussed. Test programs and analytical correlation are considered along with composite tubing advantages such as minimum weight, thermal efficiency and safety and reliability.

Hall, C. A.↗

NASA NTRS1977

A hermetic sealing process for large irregularly shaped hybrid microcircuit enclosures

A system for sealing vacuum baked hybrids in a dry inert atmosphere using an overlapping spot resistance weld is described. A unique electrode configuration and fixturing that permits sealing of large and irregularly shaped gold plated Kovar packages to the hermeticity requirements of MIL-STD-883 was discussed. Metallurgical considerations and comparisons to laser sealing were made. Problems encountered during the development and optimization of the process were highlighted. Solutions to plating, fixturing, warpage, weld splatter and cracked bead problems are presented.

Stahler, M. R.↗

NASA NTRS1979

High temperature - low mass solar blanket

Interconnect materials and designs for use with ultrathin silicon solar cells are discussed, as well as the results of an investigation of the applicability of parallel-gap resistance welding for interconnecting these cells. Data relating contact pull strength and cell electrical degradation to variations in welding parameters such as time, voltage and pressure are presented. Methods for bonding ultrathin cells to flexible substances and for bonding thin (75 micrometers) covers to these cells are described. Also, factors influencing fabrication yield and approaches for increasing yield are discussed. The results of vacuum thermal cycling and thermal soak tests on prototype ultrathin cell test coupons and one solar module blanket are presented.

Mesch, H. G.↗

NASA NTRS1979

High temperature, low mass solar blanket development

This paper presents methods of incorporating ultrathin silicon solar cells into photovoltaic blankets for space applications. This type of cell has the highest power-to-mass ratio and best performance under space radiation of any silicon solar cell. Interconnect materials and designs, and the results of the investigation of the applicability of parallel-gap resistance welding for interconnecting ultrathin cells are discussed. Data relating contact pull strength and cell electrical degradation to welding parameters such as time, voltage, and pressure are presented. Methods for bonding ultrathin cells to flexible substrates and for bonding thin covers to these cells are described, and the results of vacuum thermal cycling and thermal soak tests on prototype ultrathin cell test coupons are included.

Mesch, H. G.↗

NASA NTRS1982

Blanket technology

It was concluded that systems requirements would force a reassessment of the conventional approach to interconnecting cells into blanket or array modules. Defense applications (hardening) were identified as the key requirement that would force a movement away from the standard method (solder) of forming array circuits. The panel also agreed that requirements associated with the impending NASA Space Station and in-bound missions would lead to alternative interconnecting approaches. It was concluded that the diverse requirements of future space missions (high temperature and extended thermal cycling) might not be met by one approach, such as parallel-gap resistance welding. The panel suggested that other options such as high temperature solders and brazing be considered for the various mission requirements that were anticipated. The panel agreed that blanket technology was potentially suitable for in-orbit annealing to temperatures of 200 C provided that conventional soldered connecting techniques were replaced by "welding".

Scott-Monck, J.↗

NASA NTRS1985

Clamp Secures Material to Cylinder Base

Two-part clamp assembled around pipe or post, ends not free. Resistance welding clamp to post and locking ring to lower part of clamp permanently fixes clamp in place, preventing thermal cycling from loosening clamp.

Tam, Y. S.↗

NASA NTRS1990

Compact Pinch Welder

Compact resistance-welding pinch gun lets one operator do jobs formerly needing two workers. Light in weight and produces repeatable, high-quality weld joints. Welding-electrode head rotates for easy positioning. Lever at top of handle activates spring to pinch electrodes together at preset welding force. Button at bottom of handle activates welding current. Cables supply electrical power.

Starck, Thomas F.↗

NASA NTRS1992

High temperature solder device for flat cables

A high temperature solder device for flat cables includes a microwelder, an anvil which acts as a heat sink and supports a flexible flat ribbon cable that is to be connected to a multiple pin connector. The microwelder is made from a modified commercially available resistance welding machine such as the Split Tip Electrode microwelder by Weltek, which consists of two separate electrode halves with a removable dielectric spacer in between. The microwelder is not used to weld the items together, but to provide a controlled compressive force on, and energy pulse to, a solder preform placed between a pin of the connector and a conductor of the flexible flat ribbon cable. When the microwelder is operated, an electric pulse will flow down one electrode, through the solder preform and back up the other electrode. This pulse of electrical energy will cause the solder preform to heat up and melt, joining the pin and conductor.

Haehner, Carl L.↗

NASA NTRS1994

Metafusion: A breakthrough in metallurgy

The Metafuse Process is a patented development in the field of thin film coatings utilizing cold fusion which results in a true inter-dispersion of dissimilar materials along a gradual transition gradient through a boundary of several hundred atomic layers. The process is performed at ambient temperatures and pressures requiring relatively little energy and creating little or no heat. The process permits a remarkable range of material combinations and joining of materials which are normally incompatible. Initial applications include titanium carbide into and onto the copper resistance welding electrodes and tungsten carbide onto the cutting edges of tool steel blades. The process is achieved through application of an RF signal of low power and is based on the theory of vacancy fusion.

Joseph, Adrian A.↗