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Joining processes for aerospace systems combine fusion welding and solid state joining during production of metal structures. Detailed characteristics of electron beam welding, plasma arc welding, diffusion welding, inertia welding and weldbond processes are discussed.
An evaluation was made of five braze filler metals for joining an aluminum-containing oxide dispersion-strengthened (ODS) alloy, TD-NiCrAl. All five braze filler metals evaluated are considered suitable for joining TD-NiCrAl in terms of wettability and flow. Also, the braze alloys appear to be tolerant of slight variations in brazing procedures since joints prepared by three sources using three of the braze filler metals exhibited similar brazing characteristics and essentially equivalent 1100 C stress-rupture properties in a brazed butt-joint configuration. Recommendations are provided for brazing the aluminum-containing ODS alloys.
A compilation is presented of NASA-developed technology in welding and joining. Topics discussed include welding equipment, techniques in welding, general bonding, joining techniques, and clamps and holding fixtures.
Three joining methods were considered for use in fabricating cooling coils for the National Transonic Facility. After analysis and preliminary testing, soldering was chosen as the cooling coil joining technique over mechanical force fit and brazing techniques. Charpy V-Notch tests, cyclic thermal tests (ambient to 77.8 K) and tensile tests at cryogenic temperatures were performed on solder joints to evaluate their structural integrity. It was determined that low temperature solder can be used to ensure good fin-to-tube contact for cooling-coil applications.
An upper plate having ink flow channels and a lower plate having a multicolored pattern are joined. The joining is accomplished without clogging any ink flow paths. A pattern having different colored parts and apertures is formed in a lower plate. Ink flow channels each having respective ink input ports are formed in an upper plate. The ink flow channels are coated with solder mask and the bottom of the upper plate is then coated with solder. The upper and lower plates are pressed together at from 2 to 5 psi and heated to a temperature of from 295 F to 750 F or enough to melt the solder. After the plates have cooled and the pressure is released, the solder mask is removed from the interior passageways by means of a liquid solvent.
An effort is currently under way by NASA Marshall Space Flight Center to upgrade the space shuttle main engine through the use of improved materials and processes. Under consideration is the use of the Langley Research Center explosive seam welding process. The objective is to demonstrate the feasibility of joining space shuttle main engine tube to fitting components in an oxygen heat exchanger, using the NASA LaRC explosive seam welding process. It was concluded that LaRC explosive joining is viable for this application; that there is no incompatability of materials; that ultrasonic inspection is the best nondestructive testing method; and that the .500 DIA joint experiences interface problems.
Explosive expansion of tubes into tubesheets has been used for over 20 years in the fabrication and repair of shell and tube heat exchangers. The use of explosives to perform these expansions has offered several distinct advantages over other methods. First, the process is fast and economical and can be performed with minimal training of personnel. Secondly, explosive forming does not cause the deleterious metallurgical effects which often result from other forming operations. In addition, the process can be performed remotely without the need for sophisticated handling equipment. The expansion of tubes into tubesheets is only one of many possible fastening and joining applications for which explosive forming can be used to achieve highly successful results. The explosive forming process and where it has been used are described. In addition, some possible adaptations to other joining applications are identified and discussed.
A six month research program entitled Feasibility of Remotely Manipulated Welding in Space - A Step in the Development of Novel Joining Technologies is performed at the Massachusetts Institute of Technology for the Office of Space Science and Applications, NASA, under Contract No. NASW-3740. The work is performed as a part of the Innovative Utilization of the Space Station Program. The final report from M.I.T. was issued in September 1983. This paper presents a summary of the work performed under this contract. The objective of this research program is to initiate research for the development of packaged, remotely controlled welding systems for space construction and repair. The research effort includes the following tasks: (1) identification of probable joining tasks in space; (2) identification of required levels of automation in space welding tasks; (3) development of novel space welding concepts; (4) development of recommended future studies; and (5) preparation of the final report.
The present paper describes an approach for the optimum sizing of single and joined wing structures that is based on representing the built-up finite element model of the structure by an equivalent beam model. The low order beam model is computationally more efficient in an environment that requires repetitive analysis of several trial designs. The design procedure is implemented in a computer program that requires geometry and loading data typically available from an aerodynamic synthesis program, to create the finite element model of the lifting surface and an equivalent beam model. A fully stressed design procedure is used to obtain rapid estimates of the optimum structural weight for the beam model for a given geometry, and a qualitative description of the material distribution over the wing structure. The synthesis procedure is demonstrated for representative single wing and joined wing structures.
A tool and process to be used in the explosive joining of tubes is disclosed. The tool consists of an initiator, a tool form, and a ribbon explosive. The assembled tool is a compact, storable, and safe device suitable for explosive joining of small, lightweight tubes down to 0.20 inch in diameter. The invention is inserted into either another tube or a tube plate. A shim or standoff between the two surfaces to be welded is necessary. Initiation of the explosive inside the tube results in a high velocity, angular collision between the mating surfaces. This collision creates surface melts and collision bonding wherein electron-sharing linkups are formed.
A joined-wing flight demonstrator aircraft has been developed at the NASA Ames Research Center in collaboration with ACA Industries. The aircraft is designed to utilize the fuselage, engines, and undercarriage of the existing NASA AD-1 flight demonstrator aircraft. The design objectives, methods, constraints, and the resulting aircraft design, called the JW-1, are presented. A wind-tunnel model of the JW-1 was tested in the NASA Ames 12-foot wind tunnel. The test results indicate that the JW-1 has satisfactory flying qualities for a flight demonstrator aircraft. Good agreement of test results with design predictions confirmed the validity of the design methods used for application to joined-wing configurations.
Joined-wing aircraft employ tandem wings having positive and negative sweep and dihedral, arranged to form diamond shapes in both plan and front views. An optimization method was applied to study the effects of joined-wing geometry parameters on structural weight. The lightest wings were obtained by increasing dihedral and taper ratio, decreasing sweep and span, increasing fraction of airfoil chord occupied by structural box, and locating the joint inboard of the front wing tip.
Hand-held gun used to join metal heat-to-shrink couplings. Uses magnetic induction (eddy currents) to produce heat in metal coupling, and thermocouple to measure temperature and signals end of process. Gun, called "toroid joining gun" concentrates high levels of heat in localized areas. Reconfigured for use on metal heat-to-shrink fitting and coupling applications. Provides rapid heating, operates on low power, lightweight and portable. Safe for use around aircraft fuel and has no detrimental effects on surrounding surfaces or objects. Reliable in any environment and under all weather conditions. Gun logical device for taking full advantage of capabilities of new metal heat-to-shrink couplings and fittings.
The differences between fully stressed and minimum-weight joined-wing structures are identified, and these differences are quantified in terms of weight, stress, and direct operating cost. A numerical optimization method and a fully stressed design method are used to design joined-wing structures. Both methods determine the sizes of 204 structural members, satisfying 1020 stress constraints and five buckling constraints. Monotonic splines are shown to be a very effective way of linking spanwise distributions of material to a few design variables. Both linear and nonlinear analyses are employed to formulate the buckling constraints. With a constraint on buckling, the fully stressed design is shown to be very similar to the minimum-weight structure. It is suggested that a fully stressed design method based on nonlinear analysis is adequate for an aircraft optimization study.
Iridium-coated rhenium (Ir/Re) provides thermal margin for high performance and long life radiation cooled rockets. Two issues that have arisen in the development of flight Ir/Re engines are the sparsity of rhenium (Re) mechanical property data (particularly at high temperatures) required for engineering design, and the inability to directly electron beam weld Re chambers to C103 nozzle skirts. To address these issues, a Re mechanical property database is being established and techniques for creating Re/C103 transition joints are being investigated. This paper discusses the tensile testing results of powder metallurgy Re samples at temperatures from 1370 to 2090 C. Also discussed is the evaluation of Re/C103 transition pieces joined by both, explosive and diffusion bonding. Finally, the evaluation of full size Re transition pieces, joined by inertia welding, as well as explosive and diffusion bonding, is detailed.
A new method for plasma enhanced microwave joining of high purity (99.8%) alumina has been developed. The controlled application of a plasma between the adjoining surfaces of two rods initially heats the microwave-low-absorbing alumina rods to temperatures high enough for them to absorb microwave energy efficiently. With this technology, the adjacent surfaces of alumina rods can be melted and welded together in less than three minutes using approximately 400 watts of microwave energy. Four point bending tests measured fracture strengths of up to 130 MPa at the joined interface. Optical and SEM micrographs indicated that exaggerated grain growth prevailed for all joints studied.
A study in collaboration between investigators at Southern University and Louisiana State University in Baton Rouge, Louisiana and NASA/MSFC is examining materials for modeling and analysis of heat-activated thermal coupling for joining composite to composite/alloy structures. The short-term objectives of this research are to develop a method for joining composite or alloy structures, as well as to study the effects of thermal stress on composite-to-alloy joints. This investigation will result in the selection of a suitable metallic alloy. Al-Li alloys have potential for this purpose in aerospace applications due to their excellent strength-to-weight ratio. The study of Al-Li and other alloys is of significant importance to this and other aerospace as well as offshore related interests. Further research will incorporate the use of computer aided design and rapid prototype hardware for conceptual design and verification of a potential composite piping delivery system.
The microstructure and mechanical properties, along with the hot-die forming and joining of Ti-47Al-2Nb-2Mn-0.8 vol% TiB, sheets (known as 47XD), produced by a low-cost rolling process, were evaluated. A near-gamma microstructure was obtained in the as-rolled condition. The microstructures of heat-treated sheets ranged from a recrystallized equiaxed near-gamma microstructure at 1,200 to 1,310 C, to a duplex microstructure at 1,350 C, to a fully lamellar microstructure at 1,376 C. Tensile behavior was determined for unidirectionally rolled and cross-rolled sheets for room temperature (RT) to 816 C. Yield stress decreased gradually with increasing deformation temperature up to 704 C; above 704 C, it declined rapidly. Ultimate tensile strength exhibited a gradual decrease up to 537 C before peaking at 704 C, followed by a rapid decline at 816 C. The modulus showed a gradual decrease with temperature, reaching approximately 72% of the RT value at 816 C. Strain to failure increased slowly from RT to 537 C; between 537 C and 704 C it exhibited a phenomenal increase, suggesting that the ductile-brittle transition temperature was below 704 C. Fracture mode changed from transgranular fracture at low temperature, to a mixture of transgranular and intergranular fracture at intermediate temperature, to ductile fracture at 816 C, coupled with dynamic recrystallization at large strains. Creep rupture response was evaluated between 649 and 816 C over the stress range of 69 to 276 MPa. Deformation parameters for steady-state creep rate and time-to-rupture were similar: activation energies of approximately 350 kJ/mol and stress exponents of approximately 4.5. Hot-die forming of sheets into corrugations was done at elevated temperatures in vacuum. The process parameters to join sheets by diffusion bonding and brazing with TiCuNi 70 filler alloy were optimized for test coupons and successfully used to fabricate large truss-core and honeycomb structures. Nondestructive evaluation methods, e.g., ultrasonic C-scans and thermography along with metallography, were used to characterize bond quality. Microstructural evaluation during heat treatment, identification of phases at the braze/matrix interface, determination of shear strengths of brazed joints, and deformation mechanisms during tensile and creep processes will be discussed.