Gravity gradient stabilization system elements and antenna structures Final report, 11 Jun. - 11 Dec. 1965
Rollable beryllium copper antenna boom with windows and interlocking seam edges
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Rollable beryllium copper antenna boom with windows and interlocking seam edges
Closed circuit television /CCTV/ system automatically guides a welding torch to position the welding arc accurately along weld seams. Digital counting and logic techniques incorporated in the control circuitry, ensure performance reliability.
Biological Isolation Garment /BIG/ is a one-piece loose fitting garment fabricated from a tightly woven, permeable, 100 percent-cotton fabric. Its headpiece, incorporates an integral oronsal respirator with 0.3-micron-particle filters, and a full width visor. All fabrication seams are sealed on the inside of the garment.
Space erectable boom with interlocked seam, perforations and coatings to provide torsional rigidity and thermal stability
Microleak detector mounted on weld seam of propellant tank of launch vehicle
Application of internal hydrostatic pressure to seam-welded circular cylindrical tanks having corner-welded, flat, circular ends forms large thin-walled high quality tanks. Form limits expansion of cylindrical portion of final tank while hemispherical ends develop freely; no external form or restraint is required to fabricate spherical tanks.
Passive microwave techniques were applied to geologic problems, in order to establish the microwave properties of representative rocks and minerals, and to examine the feasibility of using microwave radiometry for geologic mapping problems. A review of microwave pertaining to geology was conducted, coupled with laboratory and field investigations of the microwave emission characteristics of various geologic features. The laboratory studies consisted of dielectric constant measurements of rocks and minerals. A majority of field investigations conducted in the western United States, involved the microwave emission charateristics of rock types, and a portion of the study was concerned with microwave properties of mineralized areas. Experiments were also conducted in the vicinity of a coal seam fire in Colorado and across the San Andreas Fault Zone near the Salton Sea, in Southern California.
A complete expulsion device was designed, fabricated, and tested in accordance with requirements specified by NASA to demonstrate the feasibility of using metallic bellows to expel liquid fluorine. Difficulties were experienced in obtaining leaktight welds at the bellows end terminals, but eventually three assemblies were successfully fabricted and cycle tested, one in LN2, two in LF2. The bellows performed well, except that they failed prematurely in LF2, apparently the result of small initiator cracks in the seam welds of the bellows.
Manufacturing processes were developed for TD-NiCr providing small sheet (45 x 90 cm), and larger sheet (60 x 150 cm) and foil. The alternate alloy, DS-NiCr, was produced by pack-chromizing Ni-ThO2 sheet. Formability criteria are being established for basic sheet forming processes, which are brake forming, corrugation forming, joggling, dimpling, and beading. Resistance spot welding (fusion and solid state), resistance seam welding, solid state diffusion welding, and brazing are included in the joining programs. Major emphasis is centered on an Al-modified Ni-Cr-ThO2 alloy development. These alloys, containing 3 to 5% Al, form the protective Al2O3 scale. This enhances oxidation resistance under reentry conditions. Both TD-NiCrAl and DS-NiCrAl alloys are included. A tentative composition of Ni-16Cr-3.5Al-2ThO2 was selected based on oxidation resistance and fabricability.
A summary is presented of the work performed by Marshall Space Flight Center (MSFC) and industry toward the development of flight-type multilayer insulation(MLI) systems. The MSFC MLI program is divided into three large categories: (1) the generation and compilation of MLI composite test data; (2) the analysis, design, and testing of heat flow through MLI applied to ducting, seams, electrical feedthroughs, structural supports, and the tank sidewall; and (3) the development, modification, and utilization of new testing procedures, tanks, and the test facilities. Numerous data have been generated, analyzed, and documented on different MLI composites.
At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding, gas-tungsten arc welding, diffusion welding, resistance spot welding, resistance seam welding, and brazing. The strengths of the welds made by the various processes show considerable variation, especially at elevated temperatures. Most of the fusion welding processes tend to give weak welds at elevated temperatures (with the exception of fusion-type resistance spotwelds). However, solid-state welds have been made with parent metal properties. The process used for a specific application will be dictated by the specific joint requirements. In highly stressed joints at elevated temperatures, one of the solid-state processes, such as DFW, RSW (solid-state or fusion), and RSEW, offer the most promise.
An improved manufacturing process has been developed for TD-NiCr that provides sheet of improved quality, better gage control, and reproducible properties. A standard manufacturing process has been developed for the alternate alloy, DS-NiCr, produced by pack-chromizing Ni-2ThO2 sheet. Extension of forming and joining technology for TD-NiCr is in process. Formability criteria are being established for basic sheet forming processes related to the manufacture of Shuttle TPS panels. They include brake forming, corrugation forming, joggling, dimpling, and beading. Joining processes applicable to TPS panels are being optimized with emphasis on establishment of joint efficiencies. Resistance spot welding (fusion and solid state), resistance seam welding, solid-state diffusion welding, and brazing are included in the joining programs. Development of improved manufacturing technology for TD-NiCr fasteners is also being accomplished. Mechanical and physical properties of TD-NiCr are being characterized to provide design-allowable data.
The effects of spacecraft installation-type discontinuities on aluminized Mylar multilayer insulation have been measured using an electrically heated cylindrical calorimeter. The experimental results have been reproducible within plus or minus 10% or better for identical blankets and less than plus or minus 5% for the same blanket. Good blanket performance can be obtained using short interleaving for joints, eliminating stitched seams, and using small patches, particularly over the hot side of stitches. The heat loss through stitching is excessive but highly localized. Analytical models matched to thermocouple test results are presented. The manner in which radiation and conduction participate in heat transfer adjacent to discontinuities is indicated. High lateral heat transfer is also established as an important phenomenon in the vicinity of a discontinuity.
Metal ribbons processed with a heat-forming treatment are enabled to form tubelike structures when deployed from a roll. Deployable booms of this have been utilized for gravity-gradient stabilization on the RAE, ATS, and Nimbus D satellites. An experimental thermal-mechanics test apparatus was developed to measure the thermal static bending and twist of booms up to 3 meters long. The apparatus was calibrated by using the correlation between calculated and observed thermal bending of a seamless tube. Thermal static bending values of 16 interlocked deployable booms were observed to be within a factor of 2.5 of the values calculated from seamless-tube theory. Out-of-Sun-plane thermal bending was caused by complex heat transfer across the interlocked seam. Significant thermal static twisting was not observed.
The SNAP 8 developmental reactor lithium hydride shield was examined after being irradiated for over 7000 hours at relatively low temperature. A crack was located in the seam weld of the containment vessel, probably the result of hot short cracking under thermal stress. The LiH was visually examined at two locations and its appearance was typical of low temperature irradiated LiH. The adherence of the chrome oxide emittance coating was found to be excellent.
At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding (EBW), gas-tungsten arc welding (GTAW), diffusion welding (DFW), resistance spot welding (RSW), resistance seam welding (RSEW), and brazing. Roll welding (RW) and explosion welding (EXW) have not been developed to the point where they can be used to make sound welds in TD-NiCr. Joining work that has previously been done on TD-NiCr by various organizations, both privately supported and under Air Force and NASA contracts, is described in this summary. Current work is also described that is being done at General Dynamics/Convair (under NASA contract) and at NASA/Lewis to develop and evaluate DFW, RSW, RSEW, and brazing. Preliminary comparisons of joining processes are made for typical applications. A brief description of the manufacture of TD-NiCr sheet by a recently standardized process (under NASA contract) also is given.
An experimental and analytical investigation of the effect of a circular hole on the buckling of thin cylindrical shells under axial compression was carried out. The experimental results were obtained from tests performed on seamless electroformed copper shells and Mylar shells with a lap joint seam. These results indicated that the character of the shell buckling was dependent on a parameter which is proportional to the hole radius divided by the square root of the product of the shell radius and thickness. For small values of this parameter, there was no apparent effect of the hole on the buckling load. For slightly larger values of the parameter, the shells still buckled into a general collapse configuration, but the buckling loads were sharply reduced as the parameter increased. For still larger values of the parameter, the buckling loads were further reduced, and the shells buckled into a stable local buckling configuration.
An ultrasonic scanning mechanism is described that scans panels of honeycomb construction or with welded seams. It incorporates a device which by simple adjustment is adapted to scan either a flat panel or a radial panel. The supporting structure takes the form of a pair of spaced rails. An immersion tank is positioned between the rails and below their level. A work holder is mounted in the tank and is adapted to hold the flat or radial panel. A traveling bridge is movable along the rails and a carriage is mounted on the bridge.