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Various technological processes to achieve lightweight reliable joining systems for structural elements of aircraft and spacecraft are considered. Joining methods, combinations of them, and nondestructive evaluation and quality assurance are emphasized.
Requirements for advanced aircraft have led to more extensive use of titanium alloys and the resultant search for joining processes which can produce lightweight, high strength airframe structures efficiently. As a result, electron beam welding has been investigated. The following F-14A components are now being EB welded in production and are mainly annealed Ti-6Al-4V except for the upper wing cover which is annealed Ti-6Al-6V-2Sn: F-14A wing center section box, and F-14A lower and upper wing covers joined to wing pivot fitting assemblies. Criteria for selection of welding processes, the EB welding facility, development work on EB welding titanium alloys, and F-14A production and sliding seal electron beam welding are reported.
A new process for joining large cross-section components by electroslag welding is reported that utilizes four consumable electrodes made of the same material as the ingots. A bifilar current supply provides the very large energy input to the consumerable nozzle for heating the ingots being welded. This process produces better and more homogeneous mechanical properties, better chemical composition and structure uniformity, and requires no prior or simultaneous heating of ingots during welding. It is now possible to obtain medium size ingots and join as many as are required to produce 500 or 600 ton ingots.
A high temperature electric resistance strain gage system was developed and evaluated to 1366 K (2000 F) for periods of at least one hour. Wire fabricated from a special high temperature strain gage alloy (BCL-3), was used to fabricate the gages. Various joining techniques (NASA butt welding, pulse arc, plasma needle arc, and dc parallel gap welding) were investigated for joining gage filaments to each other, gage filaments to lead-tab ribbons, and lead-tab ribbons to lead wires. The effectiveness of a clad-wire concept as a means of minimizing apparent strain of BCL-3 strain gages was investigated by sputtering platinum coatings of varying thicknesses on wire samples and establishing the optimum coating thickness--in terms of minimum resistivity changes with temperature. Finally, the moisture-proofing effectiveness of barrier coatings subjected to elevated temperatures was studied, and one commercial barrier coating (BLH Barrier H Waterproofing) was evaluated.
A compilation is presented which supplies technical information on the assembly of diverse components into functional assemblies and subassemblies, as well as information on several fasteners and fastening techniques that join components, subassemblies, and complete assemblies to achieve a functional unit. Quick-disconnect fasteners are described, along with several devices and methods for attaching thermal insulators, and for joining and separating objects in the absence of gravity.
An engineering prototype docking and retrieval mechanism (DRM) which enables two spacecraft to dock and be structurally joined on-orbit is described. The joining of two spacecraft or payloads on-orbit supports future planned space activities such as payload servicing, deployment and retrieval, and assembly or large space systems. Advantages of the DRM include: it is a nonimpact docking mechanism; does not require impact absorbing mechanisms or attitude stabilization on the target spacecraft; is capable of docking to a spinning spacecraft; and can spin up and deploy a spinning spacecraft or payload.
A simple, economical and reliable entry closure is described for joining opposite halves of a torso section for a pressure suit in a manner which simplifies self-donning. A single coupling joins coaxially aligned, axially separable, tubular segments of a hard spacesuit along an angulated zone of separation, adapted to be mated in an hermetrically sealing relation. A releasable C section clamp secures the members in their mated relationship.
Near-liquidus phase relations in the magnesium-rich portion of the system anorthite-forsterite-fayalite-silica have been determined from synthesis experiments at 1 atm and 2 kbar at oxygen fugacities near the iron-wuestite buffer. The major-element chemistries of KREEP basalts are similar to peritectic liquids, L/ol,px,an/, produced experimentally. The reaction L/ol,px,an/ is well-located at low pressures. It intersects the join anorthite-enstatite-ferrosilite at Fe/(Fe+Mg) equals 0.45 (atomic ratio), and is peritectic only for Fe/(Fe+Mg) not greater than 0.45. Although positions of the equilibria, L/an,ol/ and L/ol,px/, differ significantly at 1 atm from their positions at 2 kbar, the position of the piercing point, L/ol,px,an/, on the anorthite-enstatite-ferrosilite join is not sensitive to pressure. The composition of liquids produced by partial melting of troctolites and pyroxenites in the lunar crustal environment will be affected by pressure, whereas liquids derived from gabbroic assemblages will not.
An engineering prototype docking and retrieval mechanism (DRM) is described which enables two spacecraft to dock and be structurally joined on-orbit. The joining of two spacecraft or payloads on-orbit supports future planned space activities such as payload servicing, deployment and retrieval, and assembly of large space systems. The DRM, as developed, provides advantages over prior approaches because it is a nonimpact docking mechanism, does not require impact absorbing mechanisms or attitude stabilization on the target spacecraft, is capable of docking to a spinning spacecraft, and can spin up and deploy a spinning spacecraft or payload.
1000 eV beam bombarding metal surfaces to be joined removes oxides and contaminants at rate of several atomic layers per second for current density of 1 mA/squ. cm. Clean surfaces can then be joined by squeezing them together. With ion-beam cleaning, mating force for strong bond is low enough to cause only 1% deformation. Conventional cold-welding requires about 70% deformation for bonding. Technique was tested successfully on aluminum to aluminum welds, copper to copper, copper to aluminum, copper to nickel, and silver to iron. Base metals failed before welds in tear test.
Low-cost, self-contained, portable welder joins plastic parts by induction heating. Welder is useable in any atmosphere or in vacuum and with most types of thermoplastic; plastic components can be joined in situ. Device is applicable to aerospace industry and in automobile, furniture, and construction industries. Power requirements are easily met by battery or solar energy. In welder, toroidal inductor transfers magnetic flux through thermoplastic to screen. Heated screen causes plastic surface on either side to melt and flow into it to form joint.
Design and process development tasks intended to demonstrate composite blade application in large high by-pass ratio turbofan engines are described. Studies on a 3.0 aspect radio space and shell construction fan blade indicate a potential weight savings for a first stage fan rotor of 39% when a hollow titanium spar is employed. An alternate design which featured substantial blade internal volume filled with titanium honeycomb inserts achieved a 14% potential weight savings over the B/M rotor system. This second configuration requires a smaller development effort and entails less risk to translate a design into a successful product. The feasibility of metal joining large subsonic spar and shell fan blades was demonstrated. Initial aluminum alloy screening indicates a distinct preference for AA6061 aluminum alloy for use as a joint material. The simulated airfoil pressings established the necessity of rigid air surfaces when joining materials of different compressive rigidities. The two aluminum alloy matrix choices both were successfully formed into blade shells.
A study was conducted to evaluate the feasibility of space erecting a 100 meter paraboloidal radio frequency reflector by joining a number of individually deployed structural modules. Three module design concepts were considered: (1) the deployable cell module (DCM); (2) the modular paraboloidal erectable truss antenna (Mod-PETA); and (3) the modular erectable truss antenna (META). With the space shuttle (STS) as the launch system, the methodology of packaging and stowing in the orbiter, and of dispensing, deploying and joining, in orbit, were studied and the necessary support equipment identified. The structural performance of the completed reflectors was evaluated and their overall operational capability and feasibility were evaluated and compared. The potential of the three concepts to maintain stable shape in the space environment was determined. Their ability to operate at radio frequencies of 1 GHz and higher was assessed assuming the reflector surface to consist of a number of flat, hexagonal facets. A parametric study was performed to determine figure degradation as a function of reflector size, flat facet size, and f/D ratio.
The defect structure of EFG ribbons was studied using EBIC, TEM and HVEM. By imaging the same areas in EBIC and HVEM, a direct correlation between the crystallographic nature of defects and their electrical properties was obtained. (1) Partial dislocations at coherent twin boundaries may or may not be electrically active. Since no microprecipitates were observed at these dislocations it is likely that the different electrical activity is a consequence of the different dislocation core structures. (2) 2nd order twin joins were observed which followed the same direction as the coherent first order twins normally associated with EFG ribbons. These 2nd order twin joins are in all cases strongly electrically active. EFG ribbons contain high concentrations of carbon. Since no evidence of precipitation was found with TEM it is suggested that the carbon may be incorporated into the higher order twin boundaries now known to exist in EFG ribbons.
Three small, impulsive solar-microwave bursts (peak fluxes 4.9, 3.0, and 0.4 sfu) were observed during 1979 September 7-9, using the Very Large Array (VLA) at 15.05 or 22.5 GHz. The data from 10 antennas distributed on three arms of the array provide the first two-dimensional burst images with spatial resolution as high as 1.0 x 0.75 arcsec. Comparison with optical data showed in the impulsive phase of all three flares, the microwave emission was dominated by a compact source located between the H-alpha kernels. In the post-impulsive phase, the microwave source was larger and elongated in a direction consistent with the orientation of the magnetic field lines joining the H-alpha kernels. These results are interpreted to imply that the initial energy release occurs near the top of the magnetic arch joining the H-alpha kernels.
Insulating layers joined by seams. Sonic welding saves time and reduces weight. Layers of blanket built up from alternating layers of polyester sheet and polyester net. Paper pattern showing lines along which layers are joined together placed over top layer.
Method of splicing single-mode optical fibers results in very low transmission losses through joined fiber ends. Coupling losses between joined optical-fiber ends only 0.1 dB. Method needs no special operator training.
A field of measured anomalies of some physical variable relative to their time averages, is partitioned in either the space domain or the time domain. Eigenvectors and corresponding principal components of the smaller dimensioned covariance matrices associated with the partitioned data sets are calculated independently, then joined to approximate the eigenstructure of the larger covariance matrix associated with the unpartitioned data set. The accuracy of the approximation (fraction of the total variance in the field) and the magnitudes of the largest eigenvalues from the partitioned covariance matrices together determine the number of local EOF's and principal components to be joined by any particular level. The space-time distribution of Nimbus-5 ESMR sea ice measurement is analyzed.