Bonding and adjoining technology: A compilation
This compilation covers NASA and AEC developed techniques covering bonding, brazing, and joining methods and technology.
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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A study of the durability of beryllium rocket engines
An experimental test program was performed to demonstrate the durability of a beryllium INTEREGEN rocket engine when operating under conditions simulating the space shuttle reaction control system. A vibration simulator was exposed to the equivalent of 100 missions of X, Y, and Z axes random vibration to demonstrate the integrity of the recently developed injector-to-chamber braze joint. An off-limits engine was hot fired under extreme conditions of mixture ratio, chamber pressure, and orifice plugging. A durability engine was exposed to six environmental cycles interspersed with hot-fire tests without intermediate cleaning, service, or maintenance. Results from this program indicate the ability of the beryllium INTEREGEN engine concept to meet the operational requirements of the space shuttle reaction control system.
Paster, R. D.↗
Materials processing in zero gravity
Manufacturing processes which are expected to show drastic changes in a space environment due to the absence of earth gravity are classified according to (1) buoyancy and thermal convection sensitive processes and (2) processes where molecular forces like cohesion and adhesion remain as the relatively strongest and hence controlling factors. Some specific process demonstration experiments carried out during the Apollo 14 mission and in the Skylab program are described. These include chemical separation by electrophoresis, the M551 metals melting experiment, the M552 exothermic brazing experiment, the M553 sphere forming experiment, the M554 composite casting experiment, and the M555 gallium arsenide crystal growth experiment.
Wuenscher, H. F.↗
Eutectic bonding of boron-aluminum structural components. II
Eutectic bonding is a diffusion brazing process developed for fabricating boron-aluminum components from composite monolayer. This process relies on the diffusion of a thin surface film of copper into the aluminum matrix to form a liquid phase when heated above the copper-aluminum eutectic temperature of 1018 F. This type of fabrication offers design flexibility in that skin thickness may be varied, the stiffness geometry and orientation can be varied, and local reinforcement can be added. In addition, this type of boron-aluminum structure offers high efficiency. Also, this method of construction can be cost-comparative with complex titanium shapes; simple tooling permits easy layup, bonding is a one-step operation, and little finish machining is required.
Niemann, J. T.↗
Convection effects on Skylab experiments M551, M552, and M553, phase C report
This report described an analysis of Skylab Experiments M551 (Metals Melting), M552 (Exothermic Brazing), and M553 (Sphere Forming). The primary objective is the study of convection in the molten metals and their attendant solidification theory. Particular attention is given to clarifying the effects of reduced gravity on molten metal flow and solidification. Based on an analysis of physical forces and solidification theory expected for ground-based and Skylab processing, low-g variations were predicted for each experiment. A comparison was then made with the Skylab results available to date. Both metallurgical analyses of other investigators and movies of ground-based and Skylab samples were utilized. Several low-g variations in Skylab processed materials were successfully predicted based on expected variations in physical forces and fluid convection. The same analysis also successfully predicted several features in the Skylab-processed materials which were identical to terrestrially-processed materials. These results are summarized in the conclusion section for each experiment.
Bourgeois, S. V.↗
Abstracts, Third Space Processing Symposium, Skylab results
Skylab experiments results are reported in abstracts of papers presented at the Third Space Processing Symposium. Specific areas of interest include: exothermic brazing, metals melting, crystals, reinforced composites, glasses, eutectics; physics of the low-g processes; electrophoresis, heat flow, and convection demonstrations flown on Apollo missions; and apparatus for containerless processing, heating, cooling, and containing materials.
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Titanium honeycomb acoustic lining structural and thermal test report
The results are presented of static, fatigue and thermal testing of titanium honeycomb acoustic panels representing the acoustic tailpipe for the Pratt and Whitney Aircraft JT8D Refan engine which is being studied for use on the Boeing 727-200 airplane. Test specimens represented the engine and tailpipe flange joints, the rail to which the thrust reverser is attached and shear specimens of the tailpipe honeycomb. Specimens were made in four different batches with variations in configuration, materials and processes in each. Static strength of all test specimens exceeded the design ultimate load requirements. Fatigue test results confirmed that aluminum brazed titanium, as used in the Refan tailpipe design, meets the fatigue durability objectives. Quality of welding was found to be critical to life, with substandard welding failing prematurely, whereas welding within the process specification exceeded the panel skin life. Initial fatigue testing used short grip length bolts which failed prematurely. These were replaced with longer bolts and subsequent testing demonstrated the required life. Thermal tests indicate that perforated skin acoustic honeycomb has approximately twice the heat transfer of solid skin honeycomb.
Joynes, D.↗
Evaluation of dispersion strengthened nickel-base alloy heat shields for space shuttle application
The design, fabrication, and testing of a full-size, full-scale TD Ni-20Cr heat shield test array in simulated mission environments is described along with the design and fabrication of two additional full-size, full-scale test arrays to be tested in flowing gas test facilities at the NASA Langley Research Center. Cost and reusability evaluations of TD Ni-20Cr heat shield systems are presented, and weight estimates of a TD Ni-20Cr heat shield system for use on a shuttle orbiter vehicle are made. Safe-line expectancy of a TD Ni-20Cr heat shield system is assessed. Non-destructive test techniques are evaluated to determine their effectiveness in quality assurance checks of TD Ni-20Cr components such as heat shields, heat shield supports, close-out panels, formed cover strips, and edge seals. Results of tests on a braze reinforced full-scale, subsize panel are included. Results show only minor structural degradation in the main TD Ni-20Cr heat shields of the test array during simulated mission test cycles.
Johnson, R., Jr.↗
Subscale, hydrogen-burning, airframe-integrated-scramjet: Experimental and theoretical evaluation of a water cooled strut airframe-integrated-scramjet: Experimental leading edge
A water-cooled leading-edge design for an engine/airframe integrated scramjet model strut leading edge was evaluated. The cooling design employs a copper cooling tube brazed just downstream of the leading edge of a wedge-shaped strut which is constructed of oxygen-free copper. The survival of the strut leading edge during a series of tests at stagnation point heating rates confirms the practicality of the cooling design. A finite difference thermal model of the strut was also proven valid by the reasonable agreement of calculated and measured values of surface temperature and cooling-water heat transfer.
Pinckney, S. Z.↗
Spacecraft materials guide
Materials which have demonstrated their suitability for space application are summarized. Common, recurring problems in encapsulants and conformal coatings, optical materials, lubrication, and bonding and joining are noted. The subjects discussed include: low density and syntactic foams, electrical encapsulants; optical glasses, interference filter, mirrors; oils, greases, lamillar lubricants; and, soldering and brazing processes.
Staugaitis, C. L.↗
Joining and fabrication of metal-matrix composite materials
Manufacturing technology associated with developing fabrication processes to incorporate metal-matrix composites into flight hardware is studied. The joining of composite to itself and to titanium by innovative brazing, diffusion bonding, and adhesive bonding is examined. The effects of the fabrication processes on the material properties and their influence on the design of YF-12 wing panels are discussed.
Royster, D. M.↗
Materials and processes for space shuttle's engines
It is pointed out that over 50 different alloys are used in construction of the space shuttle main engines (SSME). Primary construction of the SSME is by welding or brazing of wrought and cast components. Welding processes involve both gas tungsten-arc welds and electron-beam welds. Electroforming has been developed as a process to fabricate and bond structural members for the SSME. Important aspects in the selection of materials and processes are related to weight saving considerations and the high-pressure hydrogen environment. Special problems and their solution in the case of various engine components are discussed, giving attention to the oxidizer preburner, the high pressure oxidizer turbopump, and the heat exchanger.
J. R. Lewis↗
Manufacturing in space and materials sciences on Skylab
Two main groups of manufacturing and materials studies were performed during the Skylab missions. The first group of experiments studied processes which are important in orbital assembly and construction, including melting, solidification, brazing, welding, and cutting. The second group concerned the manufacture of specific materials, including metallic alloys, single crystals, doped semiconductors, composite materials, and multicomponent superconductors. The present paper discusses several specific experiments conducted on Skylab. In general, the processes tested produced materials of higher quality in space than they would have on earth. The experiments prove that the elimination of gravitational forces has a decisive effect on a number of materials processes.
Stuhlinger, E.↗
Combined joining process for dissimilar metals: A concept
Combined brazing and diffusion bonding process for aluminum and stainless steel saves time and simplifies processing. Test show that resulting bond can withstand internal pressures up to 1,000 psi.
Beuyukian, C. S.↗
Roll-forming tubes to header plates
Technique has been developed for attaching and sealing tubes to header plates using a unique roll-forming tool. Technique is useful for attaching small tubes which are difficult to roll into conventional grooves in header plate tube holes, and for attaching when welding, brazing, or soldering is not desirable.
Kramer, K.↗
Technique for joining metal tubing
Uniform wall thickness and uninterrupted heat transfer is achieved by using shaped metal insert as wall material for joint. Insert acts as support during brazing, after which excess material is ground away to bring joint to original tubing size.
Wright, H. W.↗
Precision centering vise
Lightweight device automatically alines stainless-steel tubing and fittings, regardless of differing diameters, prior to joining via induction brazing. Device is useful in remote areas where existing supports or walls cannot be used to anchor tubing holder.
Thompson, J. A.↗
Evaluation of dispersion strengthened nickel-base alloy heat shields for space shuttle application
The results obtained in a program to evaluate dispersion-strengthened nickel-base alloys for use in a metallic radiative thermal protection system operating at surface temperatures to 1477 K for the space shuttle were presented. Vehicle environments having critical effects on the thermal protection system are defined; TD Ni-20Cr characteristics of material used in the current study are compared with previous results; cyclic load, temperature, and pressure effects on sheet material residual strength are investigated; the effects of braze reinforcement in improving the efficiency of spotwelded joints are evaluated; parametric studies of metallic radiative thermal protection systems are reported; and the design, instrumentation, and testing of full scale subsize heat shield panels in two configurations are described. Initial tests of full scale subsize panels included simulated meteoroid impact tests, simulated entry flight aerodynamic heating, programmed differential pressure loads and temperatures simulating mission conditions, and acoustic tests simulating sound levels experienced during boost flight.
Johnson, R., Jr.↗