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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Investigation of Abnormal Grain Growth in a Friction Stir Welded and Spin-Formed Al-Li Alloy 2195 Crew Module

In order to improve manufacturing efficiency and reduce structural mass and costs in the production of launch vehicle structures, NASA is pursuing a wide-range of innovative, near-net shape manufacturing technologies. A technology that combines friction stir welding (FSW) and spin-forming has been applied to manufacture a single-piece crew module using Aluminum-Lithium (AL-Li) Alloy 2195. Plate size limitations for Al-Li alloy 2195 require that two plates be FSW together to produce a spin-forming blank of sufficient size to form the crew module. Subsequent forming of the FSW results in abnormal grain growth (AGG) within the weld region upon solution heat treatment (SHT), which detrimentally impacts strength, ductility, and fracture toughness. The current study seeks to identify microstructural factors that contribute to the development of AGG. Electron backscatter diffraction (EBSD) was used to correlate driving forces for AGG, such as stored energy, texture, and grain size distributions, with the propensity for AGG. Additionally, developmental annealing treatments prior to SHT are examined to reduce or eliminate the occurrence of AGG by promoting continuous, or uniform, grain growth

Tayon, Wesley A.↗
NASA NTRS2010

Simulated Service and Stress Corrosion Cracking Testing for Friction Stir Welded Spun Formed Domes

Simulated service testing (SST) development was required to help qualify a new 2195 aluminum lithium (Al-Li) alloy spin forming dome fabrication process for the National Aeronautics and Space Administration (NASA) Exploration Development Technology Program. The application for the technology is to produce high strength low weight tank components for NASA s next generation launch vehicles. Since plate material is not currently manufactured large enough to fabricate these domes, two plates are joined by means of friction stir welding. The plates are then pre-contour machined to near final thicknesses allowing for a thicker weld land and anticipating the level of stretch induced by the spin forming process. The welded plates are then placed in a spin forming tool and hot stretched using a trace method producing incremental contours. Finally the dome receives a room temperature contour stretch to final dimensions, heat treatment, quenching, and artificial aging to emulate a T-8 condition of temper. Stress corrosion cracking (SCC) tests were also performed by alternate immersion in a sodium chloride (NaCl) solution using the typical double beam assembly and with 4-point loaded specimens and use of bent-beam stress-corrosion test specimens under alternate immersion conditions. In addition, experiments were conducted to determine the threshold stress intensity factor for SCC (K(sub ISCC)) which to our knowledge has not been determined previously for Al-Li 2195 alloy. The successful simulated service and stress corrosion testing helped to provide confidence to continue to Ares 1 scale dome fabrication

Stewart, Thomas J.↗
NASA NTRS2004

Aluminum-Scandium Alloys: Material Characterization, Friction Stir Welding, and Compatibility With Hydrogen Peroxide (MSFC Center Director's Discretionary Fund Final Report, Proj. No. 04-14)

This Technical Memorandum describes the development of several high-strength aluminum (Al) alloys that are compatible with hydrogen peroxide (H2O2) propellant for NASA Hypersonic-X (Hyper-X) vehicles fuel tanks and structures. The yield strengths for some of these Al-magnesium-based alloys are more than 3 times stronger than the conventional 5254-H112 Al alloy, while maintaining excellent H2O2 compatibility similar to class 1 5254 alloy. The alloy development strategy is to add scandium, zirconium, and other transitional metals with unique electrochemical properties, which will not act as catalysts, to decompose the highly concentrated 90 percent H2O2. Test coupons are machined from sheet metals for H2O2 long-term exposure testing and mechanical properties testing. In addition, the ability to weld the new alloys using friction stir welding has also been explored. The new high-strength alloys could represent an enabling material technology for Hyper-X vehicles, where flight weight reduction is a critical requirement.

Lee, J. A.↗
NASA NTRS2010

Large Spun Formed Friction-Stir Welded Tank Domes for Liquid Propellant Tanks Made from AA2195: A Technology Demonstration for the Next Generation of Heavy Lift Launchers

Improving structural efficiency while reducing manufacturing costs are key objectives when making future heavy-lift launchers more performing and cost efficient. The main enabling technologies are the application of advanced high performance materials as well as cost effective manufacture processes. This paper presents the status and main results of a joint industrial research & development effort to demonstrate TRL 6 of a novel manufacturing process for large liquid propellant tanks for launcher applications. Using high strength aluminium-lithium alloy combined with the spin forming manufacturing technique, this development aims at thinner wall thickness and weight savings up to 25% as well as a significant reduction in manufacturing effort. In this program, the concave spin forming process is used to manufacture tank domes from a single flat plate. Applied to aluminium alloy, this process allows reaching the highest possible material strength status T8, eliminating numerous welding steps which are typically necessary to assemble tank domes from 3D-curved panels. To minimize raw material costs for large diameter tank domes for launchers, the dome blank has been composed from standard plates welded together prior to spin forming by friction stir welding. After welding, the dome blank is contoured in order to meet the required wall thickness distribution. For achieving a material state of T8, also in the welding seams, the applied spin forming process allows the required cold stretching of the 3D-curved dome, with a subsequent ageing in a furnace. This combined manufacturing process has been demonstrated up to TRL 6 for tank domes with a 5.4 m diameter. In this paper, the manufacturing process as well as test results are presented. Plans are shown how this process could be applied to future heavy-lift launch vehicles developments, also for larger dome diameters.

Stachulla, M.↗
NASA NTRS2008

Friction-Stir Welding - Heavy Inclusions in Bi-metallic welds of Al 2219/2195

Heavy Inclusions (HI) were detected for the first time by radiographic examination in aluminum alloy 2219forging/2195plate (advancing/retreating side) Friction Sir Welds (FSW) for the Space Shuttle External Tank (ET) Program. Radiographic HI indications appear as either small (approx.0.005"-0.025") individual particles or clusters of small particles. Initial work was performed to verify that the HI was not foreign material or caused by FSW pin tool debris. That and subsequent elemental analysis determined that the HI were large agglomerations of Al2Cu (theta phase), which is the strengthening precipitate in Al2219. A literature search on that subject determined that the agglomeration of phase has also been found in Al2219 bead on plate FSW [Ref. 1]. Since this was detected in ET space flight hardware, an investigative study of the effect of agglomerated theta phase particles in FSW Al2219f/2195p was performed. Numerous panels of various lengths were welded per ET weld procedures and radiographically inspected to determine if any HI was detected. Areas that had HI were sampled for room temperature and cyclic cryogenic (-423F) tensile testing and determined no significant adverse affect on mechanical properties when compared to test specimens without HI and historical data. Fracture surface examination using the Scanning Electron Microscope (SEM) revealed smaller phase agglomerations undetectable by radiographic inspection dispersed throughout the Al2219f/2195p FSW. This indicates that phase agglomeration is inherent to the Al2219f/2195p FSW process and only rarely creates agglomerations large enough to be detected by radiography. HI has not been observed in FSW of plate to plate material for either Al2219 or AL2195.

Rietz, Ward W., Jr.↗
NASA NTRS1999

Assembly of a Full-Scale External Tank Barrel Section Using Friction Stir Welding

A full-scale pathfinder barrel section of the External Tank for the National Aeronautics and Space Administration (NASA) Space Transport System (Space Shuttle) has been assembled at Marshall Space Flight Center (MSFC) via a collaborative effort between NASA/MSFC and Lockheed Martin Michoud Space Systems. The barrel section is 27.5 feet in diameter and 15 feet in height. The barrel was assembled using Super-Light-Weight (SLWT), orthogrid, Al-Li 2195 panel sections and a single longeron panel. A vertical weld tool at MSFC was modified to accommodate FSW and used to assemble the barrel. These modifications included the addition of a FSW weld head and new controller hardware and software, the addition of a backing anvil and the replacement of the clamping system with individually actuated clamps. Weld process 4evelopment was initially conducted to optimize the process for the welds required for completing the assembly. The variable thickness welds in the longeron section were conducted via both two-sided welds and with the use of a retractable pin tool. The barrel assembly was completed in October 1998. Details of the vertical weld tool modifications and the assembly process are presented.

Jones, Chip↗
NASA NTRS2000

Fatigue Crack Growth Rate Test Results for Al-Li 2195 Parent Metal, Variable Polarity Plasma Arc Welds and Friction Stir Welds

The fatigue crack growth rate of aluminum-lithium (Al-Li) alloy 2195 plate and weldments was determined at 200-F, ambient temperature and -320-F. The effects of stress ratio (R), welding process, orientation and thickness were studied. Results are compared with plate data from the Space Shuttle Super Lightweight Tank (SLWT) allowables program. Data from the current series of tests, both plate and weldment, falls within the range of data generated during the SLWT allowables program.

Hafley, Robert A.↗
NASA NTRS2000

Demonstration of a Large-Scale Tank Assembly Via Circumferential Friction Stir Welds

Five (5) each 14-foot diameter circumferential FSWelds were conducted on the modified CWT, two (2) each pathfinder and three (3) each assembly welds Tapered circumferential welds were successfully demonstrated The use of a closeout anvil was successfully demonstrated during one of the pathfinder welds Considerable difficulty maintaining joint f it-up during the weld process Anvil deflections Hardware dimensional tolerances Inadequate clamping Variations in the heat sink characteristics of the circumferential anvil as compared to the test panel anvil

Jones, Chip↗
NASA NTRS2001

Development of a Novel Method for Determination of Residual Stresses in a Friction Stir Weld

Material constitutive properties, which describe the mechanical behavior of a material under loading, are vital to the design and implementation of engineering materials. For homogeneous materials, the standard process for determining these properties is the tensile test, which is used to measure the material stress-strain response. However, a majority of the applications for engineering materials involve the use of heterogeneous materials and structures (i.e. alloys, welded components) that exhibit heterogeneity on a global or local level. Regardless of the scale of heterogeneity, the overall response of the material or structure is dependent on the response of each of the constituents. Therefore, in order to produce materials and structures that perform in the best possible manner, the properties of the constituents that make up the heterogeneous material must be thoroughly examined. When materials exhibit heterogeneity on a local level, such as in alloys or particle/matrix composites, they are often treated as statistically homogenous and the resulting 'effective' properties may be determined through homogenization techniques. In the case of globally heterogeneous materials, such as weldments, the standard tensile test provides the global response but no information on what is Occurring locally within the different constituents. This information is necessary to improve the material processing as well as the end product.

Reynolds, Anthony P.↗
NASA NTRS2003

Space Shuttle ET Friction Stir Weld Machines

NASA and Lockheed-Martin approached the FSW machine vendor community with a specification for longitudinal barrel production FSW weld machines and a shorter travel process development machine in June of 2000. This specification was based on three years of FSW process development on the Space Shuttle External Tank alloys, AL2 195-T8M4 and AL22 19-T87. The primary motivations for changing the ET longitudinal welds from the existing variable polarity Plasma Arc plasma weld process included: (1) Significantly reduced weld defect rates and related reduction in cycle time and uncertainty; (2) Many fewer process variables to control (5 vs. 17); (3) Fewer manufacturing steps; (4) Lower residual stresses and distortion; (5) Improved weld strengths, particularly at cryogenic temperatures; (6) Fewer hazards to production personnel. General Tool was the successful bidder. The equipment is at this writing installed and welding flight hardware. This paper is a means of sharing with the rest of the FSW community the unique features developed to assure NASA/L-M of successful production welds.

Thompson, Jack M.↗
NASA NTRS2003

2XXX Aluminum Self Reacting Friction Stir Weld Development

Weld process development are: (1) Execute a two-phased design of experiment (DOE) approach: process DOE to establish rotation and travel speeds and forge load;set-up DOE to establish allowable gap and centerline offset. (2) Determine the effect of process parameters on strength and weld quality: room and -320 deg F tensile testing; metalllurgical and NDE evaluation. (3) Weld quality goals: visual and radiographic acceptable; room temperature ultimate strength.

Brown, Randy J.↗
NASA NTRS2003

Friction Stir Process Mapping Methodology

The weld process performance for a given weld joint configuration and tool setup is summarized on a 2-D plot of RPM vs. IPM. A process envelope is drawn within the map to identify the range of acceptable welds. The sweet spot is selected as the nominal weld schedule The nominal weld schedule is characterized in the expected manufacturing environment. The nominal weld schedule in conjunction with process control ensures a consistent and predictable weld performance.

Bjorkman, Gerry↗
NASA NTRS2006

A Rotating Plug Model of Friction Stir Welding Heat Transfer

A simplified rotating plug model is employed to study the heat transfer phenomena associated with the fiction stir welding process. An approximate analytical solution is obtained based on this idealized model and used both to demonstrate the qualitative influence of process parameters on predictions and to estimate temperatures produced in typical fiction stir welding situations.

Raghulapadu J. K.↗
NASA NTRS2006

A Decade of Friction Stir Welding R and D at NASA's Marshall Space Flight Center and a Glance into the Future

Welding at NASA's Marshall Space Flight Center (MSFC), Huntsville, Alabama, has taken a new direction through the last 10 years. Fusion welding processes, namely variable polarity plasma arc (VPPA) and tungsten inert gas (TIG) were once the corner stone of welding development in the Space Flight Center's welding laboratories, located in the part of MSFC know as National Center for Advanced Manufacturing (NCM). Developed specifically to support the Shuttle Program's External Tank and later International Space Station manufacturing programs, was viewed as the paragon of welding processes for joining aluminum alloys. Much has changed since 1994, however, when NASA's Jeff Ding brought the FSW process to the NASA agency. Although, at that time, FSW was little more than a "lab curiosity", NASA researchers started investigating where the FSW process would best fit NASA manufacturing programs. A laboratory FSW system was procured and the first welds were made in fall of 1995. The small initial investment NASA made into the first FSW system has certainly paid off for the NASA agency in terms of cost savings, hardware quality and notoriety. FSW is now a part of Shuttle External Tank (ET) production and the preferred weld process for the manufacturing of components for the new Crew Launch Vehicle (CLV) and Heavy Lift Launch Vehicle (HLLV) that will take this country back to the moon. It is one of the solid state welding processes being considered for on-orbit space welding and repair, and is of considerable interest for Department of Defense @OD) manufacturing programs. MSFC involvement in these and other programs makes NASA a driving force in this country's development of FSW and other solid state welding technologies. Now, a decade later, almost the entire on-going welding R&D at MSFC now focuses on FSW and other more advanced solid state welding processes.

Ding, Jeff↗
NASA NTRS2009

Laser Peening Effects on Friction Stir Welding

The laser peening process can result in considerable improvement to crack initiation, propagation, and mechanical properties in FSW which equates to longer hardware service life Processed hardware safety is improved by producing higher failure tolerant hardware, and reducing risk. Lowering hardware maintenance cost produces longer hardware service life, and lower hardware down time. Application of this proposed technology will result in substantial benefits and savings throughout the life of the treated components

Hatameleh, Omar↗
NASA NTRS2009

The Establishment of a New Friction Stir Welding Process Development Facility at NASA/MSFC

Full-scale weld process development is being performed at MSFC to develop the tools, fixtures, and facilities necessary for Ares I production. Full scale development in-house at MSFC fosters technical acuity within the NASA engineering community, and allows engineers to identify and correct tooling and equipment shortcomings before they become problems on the production floor. Finally, while the new weld process development facility is currently being outfitted in support of Ares I development, it has been established to support all future Constellation Program needs. In particular, both the RWT and VWT were sized with the larger Ares V hardware in mind.

Carter, Robert W.↗
NASA NTRS2010

Simulated Service and Stress Corrosion Cracking Testing for Friction Stir Welded Spun Form Domes

Damage tolerance testing development was required to help qualify a new spin forming dome fabrication process for the Ares 1 program at Marshall Space Flight Center (MSFC). One challenge of the testing was due to the compound curvature of the dome. The testing was developed on a sub-scale dome with a diameter of approximately 40 inches. The simulated service testing performed was based on the EQTP1102 Rev L 2195 Aluminum Lot Acceptance Simulated Service Test and Analysis Procedure generated by Lockheed Martin for the Space Shuttle External Fuel Tank. This testing is performed on a specimen with an induced flaw of elliptical shape generated by Electrical Discharge Machining (EDM) and subsequent fatigue cycling for crack propagation to a predetermined length and depth. The specimen is then loaded in tension at a constant rate of displacement at room temperature until fracture occurs while recording load and strain. An identical specimen with a similar flaw is then proof tested at room temperature to imminent failure based on the critical offset strain achieved by the previous fracture test. If the specimen survives the proof, it is then subjected to cryogenic cycling with loads that are a percentage of the proof load performed at room temperature. If all cryogenic cycles are successful, the specimen is loaded in tension to failure at the end of the test. This standard was generated for flat plate, so a method of translating this to a specimen of compound curvature was required. This was accomplished by fabricating a fixture that maintained the curvature of the specimen rigidly with the exception of approximately one-half inch in the center of the specimen containing the induced flaw. This in conjunction with placing the center of the specimen in the center of the load train allowed for successful testing with a minimal amount of bending introduced into the system. Stress corrosion cracking (SCC) tests were performed using the typical double beam assembly and with 4-point loaded specimens under alternate immersion conditions in a 3.5% NaCl environment for 90 days. In addition, experiments were conducted to determine the threshold stress intensity factor for SCC (K1SCC) of Al-Li 2195 which to our knowledge has not been determined previously. The successful simulated service and stress corrosion testing helped to provide confidence to continue to Ares 1 scale dome fabrication.

Stewart, Thomas J.↗