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Process produces continuous internal channel systems on a repeatable basis in 2014-T6 aluminum. Standard machining forms the initial channel, which is filled with tungsten carbide powder. TIG machine fusion welding completes formation of the channel. Chem-mill techniques enlarge it to the desired size.
Tool with stepped shoulders alines tubes for machining in preparation for welding. Alinement with machine tool axis accurate to within 5 mils (0.13mm) and completed much faster than visual setup by machinist.
The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled.
A regeneratively cooled thrust chamber has been designed and fabricated, consisting of an inner TD nickel liner which was spin formed, welded, and machined and an outer shell of electroformed nickel. Coolant channels were produced in the outer surface of the inner liner by the electric discharge machining process before electroforming the shell. Accessory manifolds and piping were attached by welding. Manufacturing processes employed are described.
Adaptive machining is method of machining large, somewhat flexible workpieces to close tolerances. Devised for machining precise weld lands on aft skirts of rocket nozzles, but underlying concept generally applicable to precise machining of any of large variety of workpieces deformed by thermal, gravitational, and/or machining forces. For example, in principle, method used to bore precise hole on unanchored end of long cantilever beam.
Welds of better quality made, and/or heat input reduced. Improved shapes devised for abutting edges of metal pieces to be joined by plasma arc welding in keyhole mode, in which gas jet maintains molten hole ("keyhole") completely through thickness of weld joint. Edges of metal pieces to be welded together machined to provide required combination gap and shaped, thin sections. Shapes and dimensions chosen to optimize weld in various respects; e.g., to enhance penetration of keyhole or reduce heat input to produce joint of given thickness.
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Spiking in electron-beam welding reduced by placing high-vapor-pressure substance along path of electron beam. Strip of metal having vapor pressure higher than base metal at same temperature placed in slot machined along weld line. Strip vaporizes as beam strikes it, and vapor pressure keeps surface tension from closing off top of channel. Technique used successfully on nickel alloys and aluminum alloys and effective on steel and titanium.
Precision positioning controls for welding saturn space vehicles
Gas-tungsten arc welding for positioning and inside-locking of liquid oxygen /LOX/ tunnel of Saturn V booster
Inert atmosphere welding chamber, discussing measurement and control of contamination
Spring-loaded clamp applies specific pressure to hold materials together during bonding, welding, and machining. The clamp has two adjustable legs terminating in suction cups for easy attachment to a surface.
Heat treatment processes, applied after welding but before machining, imparts above normal stability to welded aluminum jigs and tool structures. Weight saving will not be realized in these tools if rigidity equal to that of a comparable steel tool is required.
Vacuum ultraviolet coatings, microcircuitry welding, metal polishing, absolute spectral response system, parabolic reflectors, and soldering to electrodeposited metals
Welding of aluminum alloy for S-1C stage of Saturn-Apollo space vehicle
Laser method, where high energies of monochromatic light can be precisely collimated to perform welding and machining processes, is proposed for rotary dynamic balancing. The unbalance, as detected with the velocity pickup, would trigger the laser system which would emit high energy pulses directed at the heavy side of the component.
Saturn booster Ti alloy pressure vessel forging, heat treatment and welding, discussing machining, cleaning and tooling
Inexpensive, readily assembled pointer aims X-ray machine for welded assembly radiographs. Plumb bob used for vertical alinement and yardstick used to visualize X-ray paths were inconvenient and inaccurate. Pointer cuts alinement time by one-half and eliminates necessity of retakes. For 3,000 weld radiographs, pointer will save 300 worker-hours and significant materials costs.