Swiss-roll Flare Gas Incinerator
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Chen, Chien-Hua [Advanced Cooling Technologies, In↗
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TRMM On-Orbit Performance Re-Accessed After Control Change
The Tropical Rainfall Measuring Mission (TRMM) spacecraft, a joint mission between the U.S. and Japan, launched onboard an HI1 rocket on November 27,1997 and transitioned in August, 2001 from an average operating altitude of 350 kilometers to 402.5 kilometers. Due to problems using the Earth Sensor Assembly (ESA) at the higher altitude, TRMM switched to a backup attitude control mode. Prior to the orbit boost TRMM controlled pitch and roll to the local vertical using ESA measurements while using gyro data to propagate yaw attitude between yaw updates from the Sun sensors. After the orbit boost, a Kalman filter used 3-axis gyro data with Sun sensor and magnetometers to estimate onboard attitude. While originally intended to meet a degraded attitude accuracy of 0.7 degrees, the new control mode met the original 0.2 degree attitude accuracy requirement after improving onboard ephemeris prediction and adjusting the magnetometer calibration onboard. Independent roll attitude checks using a science instrument, the Precipitation Radar (PR) which was built in Japan, provided a novel insight into the pointing performance. The PR data helped identify the pointing errors after the orbit boost, track the performance improvements, and show subtle effects from ephemeris errors and gyro bias errors. It also helped identify average bias trends throughout the mission. Roll errors tracked by the PR from sample orbits pre-boost and post-boost are shown in Figure 1. Prior to the orbit boost the largest attitude errors were due to occasional interference in the ESA. These errors were sometime larger than 0.2 degrees in pitch and roll, but usually less, as estimated from a comprehensive review of the attitude excursions using gyro data. Sudden jumps in the onboard roll show up as spikes in the reported attitude since the control responds within tens of seconds to null the pointing error. The PR estimated roll tracks well with an estimate of the roll history propagated using gyro data. After the orbit boost, the attitude errors shown by the PR roll have a smooth sine-wave type signal because of the way that attitude errors propagate with the use of gyro data. Yaw errors couple at orbit period to roll with '/4 orbit lag. By tracking the amplitude, phase, and bias of the sinusoidal PR roll error signal, it was shown that the average pitch rotation axis tends to be offset from orbit normal in a direction perpendicular to the Sun direction, as shown in Figure 2 for a 200 day period following the orbit boost. This is a result of the higher accuracy and stability of the Sun sensor measurements relative to the magnetometer measurements used in the Kalman filter. In November, 2001 a magnetometer calibration adjustment was uploaded which improved the pointing performance, keeping the roll and yaw amplitudes within about 0.1 degrees. After the boost, onboard ephemeris errors had a direct effect on the pitch pointing, being used to compute the Earth pointing reference frame. Improvements after the orbit boost have kept the the onboard ephemeris errors generally below 20 kilometers. Ephemeris errors have secondary effects on roll and yaw, especially during high beta angle when pitch effects can couple into roll and yaw. This is illustrated in figure 3. The onboard roll bias trends as measured by PR data show correlations with the Kalman filter's gyro bias error. This particularly shows up after yaw turns (every 2 to 4 weeks) as shown in Figure 3, when a slight roll bias is observed while the onboard computed gyro biases settle to new values. As for longer term trends, the PR data shows that the roll bias was influenced by Earth horizon radiance effects prior to the boost, changing values at yaw turns, and indicated a long term drift as shown in Figure 4. After the boost, the bias variations were smaller and showed some possible correlation with solar beta angle, probably due to sun sensor misalignment effects.
Bilanow, Steve↗
Conical Euler simulation and active suppression of delta wing rocking motion
A conical Euler code was developed to study unsteady vortex-dominated flows about rolling highly-swept delta wings, undergoing either forced or free-to-roll motions including active roll suppression. The flow solver of the code involves a multistage Runge-Kutta time-stepping scheme which uses a finite volume spatial discretization of the Euler equations on an unstructured grid of triangles. The code allows for the additional analysis of the free-to-roll case, by including the rigid-body equation of motion for its simultaneous time integration with the governing flow equations. Results are presented for a 75 deg swept sharp leading edge delta wing at a freestream Mach number of 1.2 and at alpha equal to 10 and 30 deg angle of attack. A forced harmonic analysis indicates that the rolling moment coefficient provides: (1) a positive damping at the lower angle of attack equal to 10 deg, which is verified in a free-to-roll calculation; (2) a negative damping at the higher angle of attack equal to 30 deg at the small roll amplitudes. A free-to-roll calculation for the latter case produces an initially divergent response, but as the amplitude of motion grows with time, the response transitions to a wing-rock type of limit cycle oscillation. The wing rocking motion may be actively suppressed, however, through the use of a rate-feedback control law and antisymmetrically deflected leading edge flaps. The descriptions of the conical Euler flow solver and the free-to-roll analysis are presented. Results are also presented which give insight into the flow physics associated with unsteady vortical flows about forced and free-to-roll delta wings, including the active roll suppression of this wing-rock phenomenon.
Lee, Elizabeth M.↗
TRMM On-Orbit Performance Reassessed After Control Change
The Tropical Rainfall Measuring Mission (TRMM) spacecraft, a joint mission between the U.S. and Japan, launched onboard an H-I1 rocket on November 27, 1997, and transitioned in August, 2001, from an average operating altitude of 350 kilometers to 402.5 kilometers. Due to problems using the Earth Sensor Assembly (ESA) at the higher altitude, TRMM switched to a backup attitude control mode. Prior to the orbit boost TRMM controlled pitch and roll to the local vertical using ESA measurements while using gyro data to propagate yaw attitude between yaw updates from the Sun sensors. After the orbit boost, a Kalman filter used 3-axis gyro data with Sun sensor and magnetometers to estimate onboard attitude. While originally intended to meet a degraded attitude accuracy of 0.7 degrees, the new control mode met the original 0.2 degree attitude accuracy requirement after improving onboard ephemeris prediction and adjusting the magnetometer calibration onboard. Independent roll attitude checks using a science instrument, the Precipitation Radar (PR) which was built in Japan, provided a novel insight into the pointing performance. The PR data helped identify the pointing errors after the orbit boost, track the performance improvements, and show subtle effects from ephemeris errors and gyro bias errors. It also helped identify average bias trends throughout the mission. Roll errors tracked by the PR from sample orbits pre-boost and post-boost are shown in Figure 1. Prior to the orbit boost, the largest attitude errors were due to occasional interference in the ESA. These errors were sometime larger than 0.2 degrees in pitch and roll, but usually less, as estimated from a comprehensive review of the attitude excursions using gyro data. Sudden jumps in the onboard roll show up as spikes in the reported attitude since the control responds within tens of seconds to null the pointing error. The PR estimated roll tracks well with an estimate of the roll history propagated using gyro data. After the orbit boost, the attitude errors shown by the PR roll have a smooth sine-wave type signal because of the way that attitude errors propagate with the use of gyro data. Yaw errors couple at orbit period to roll with 1/4 orbit lag. By tracking the amplitude, phase, and bias of the sinusoidal PR roll error signal, it was shown that the average pitch rotation axis tends to be offset from orbit normal in a direction perpendicular to the Sun direction, as shown in Figure 2 for a 200 day period following the orbit boost. This is a result of the higher accuracy and stability of the Sun sensor measurements relative to the magnetometer measurements used in the Kalman filter. In November, 2001 a magnetometer calibration adjustment was uploaded which improved the pointing performance, keeping the roll and yaw amplitudes within about 0.1 degrees.
Bilanow, Stephen↗
A Pilot Opinion Study of Lateral Control Requirements for Fighter-Type Aircraft
As part of a continuing NASA program of research on airplane handling qualities, a pilot opinion investigation has been made on the lateral control requirements of fighter aircraft flying in their combat speed range. The investigation was carried out using a stationary flight simulator and a moving flight simulator, and the flight simulator results were supplemented by research tests in actual flight. The flight simulator study was based on the presumption that the pilot rates the roll control of an airplane primarily on a single-degree-of-freedom basis; that is, control of angle of roll about the aircraft body axis being of first importance. From the assumption of a single degree of freedom system it follows that there are two fundamental parameters which govern the airplane roll response, namely the roll damping expressed as a time constant and roll control power in terms of roll acceleration. The simulator study resulted in a criterion in terms of these two parameters which defines satisfactory, unsatisfactory, and unacceptable roll performance from a pilot opinion standpoint. The moving simulator results were substantiated by the in-flight investigation. The derived criterion was compared with the roll performance criterion based upon wing tip helix angle and also with other roll performance concepts which currently influence the roll performance design of military fighter aircraft flying in their combat speed range.
Creer, Brent Y.↗
Open ended tubing cutters
A self clamping cutting tool which includes a handle attached to a C-shaped housing is described. Rotatably mounted within the housing is a C-shaped tool body carrying a set of clamping rolls, two support rolls, and an edged cutting roll (64). The support rolls are disposed to one side of the axis of a pipe and the cutting roll is disposed to the other side of a pipe axis so that these rolls contact a pipe at three circumferential points. Cutter advancing apparatus advance the cutting roll toward the support rollers. The support rolls and cutting roll are rotatable independently of the C-shaped housing. A one way ratchet mechanism disposed between the C-shaped housing and the C-shaped tool body permits operation by movement in one rotational direction about the pipe axis.
Girala, A. S.↗
The measurement and improvement of the lateral agility of the F-18
The effect of vehicle configuration and flight control system performance on the roll agility of a modern fighter aircraft has been investigated. A batch simulation of a generic F-18 Hornet was used to study the roll agility as measured by the time to roll through 90 deg metric. Problems discussed include definition of agility, factors affecting the agility of a vehicle, the development of the time to roll through 90 deg agility metric, and a simulation experiment. It is concluded that the integral of stability or wind axis roll rate should be used as a measure of the roll measure traversed. The time through roll angle 90 deg metric is considered to be a good metric for measuring the transient performance aspect of agility. Roll agility of the F-18, as measured by 90 deg metric, can be improved by 10 to 30 percent. Compatible roll and rudder actuator rates can significantly affect 90 deg agility metric.
Eggold, David P.↗
Unsteady, Transonic Flow Around Delta Wings Undergoing Coupled and Natural Modes Response: A Multidisciplinary Problem
The unsteady, three-dimensional Navier-Stokes equations coupled with the Euler equations of rigid-body dynamics are sequentially solved to simulate and analyze the aerodynamic response of a high angle of attack delta wing undergoing oscillatory motion. The governing equations of fluid flow and dynamics of the multidisciplinary problem are solved using a time-accurate solution of the laminar, unsteady, compressible, full Navier- Stokes equations with the implicit, upwind, Roe flux-difference splitting, finite-volume scheme and a four-stage Runge-Kutta scheme, respectively. The primary model under consideration consists of a 65 deg swept, sharp-edged, cropped delta wing of zero thickness at 20 deg angle of attack. In a freestream of Mach 0.85 and Reynolds number of 3.23 x 10(exp 6), the flow over the upper surface of the wing develops a complex shock system which interacts with the leading-edge primary vortices producing vortex breakdown. The effect of the oscillatory motion of the wing on the vortex breakdown and overall aerodynamic response is detailed to provide insight to the complicated physics associated with unsteady flows and the phenomenon of wing rock. Forced sinusoidal single and coupled mode rolling and pitching motion is presented for the wing in a transonic freestream. The Reynolds number, frequency of oscillation, and the phase angle are varied. Comparison between the single and coupled mode forced rolling and pitching oscillation cases illustrate the effects of coupling the motion. This investigation shows that even when coupled, forced rolling oscillation at a reduced frequency of 2(pi) eliminates the vortex breakdown which results in an increase in lift. The coupling effect for in phase forced oscillations show that the lift coefficient of the pitching-alone case and the rolling-moment coefficient of the rolling-alone case dominate the resulting response. However, with a phase lead in the pitching motion, the coupled motion results in a non-periodic response of the rolling moment. The second class of problems involve releasing the wing in roll to respond to the flowfield. Two models of sharp-edged delta wings, the previous 65 deg swept model and an 80 deg swept, sharp-edged delta wing, are used to observe the aerodynamic response of a wing free to roll in a transonic and subsonic freestream, respectively. These cases demonstrate damped oscillations, self-sustained limit cycle oscillations, and divergent rolling oscillations. Ultimately, an active control model using a mass injection system was applied on the surface of the wing to suppress the self-sustained limit cycle oscillation known as wing rock. Comparisons with experimental investigations complete this study, validating the analysis and illustrating the complex details afforded by computational investigations.
Menzies, Margaret Anne↗
Progress in Navier-Stokes Simulation of Delta Wing Maneuver Aerodynamics
This paper will summarize recent progress in the numerical simulation of high incidence vortical flow about a generic 65 degree sweep delta wing using the three dimensional, time-dependent, Reynolds averaged, Navier-Stokes (RANS) equations. Computations have been carried out at 15 and 30 degrees angle of attack under subsonic turbulent flow conditions, and compared with experimental data provided by Hanff, Jenkins, and their colleagues. This work has already been published elsewhere and widely disseminated. Computations carried out at 15 degrees angle of attack included static roll angles ranging up to 65 degrees, and a large-amplitude (40 degree), high rate (7 Hz), forced roll motion. There was very good agreement between computed and experimental forces and moments, and static surface pressures. There was a significant hysteresis of the dynamic rolling moment due to the high rate of roll motion. At this angle of attack, no vortex breakdown was observed in the computations or experiment. Computations were also carried out at 30 degrees angle of attack, where vortex breakdown was present in both the computations and experiment. There was overall good agreement in the computed and experimental forces and moments. The static rolling moment varied with roll angle in a highly nonlinear manner, and exhibited three stable trim points and two unstable trim points. This behavior was attributed to the presence of vortex breakdown. Two large-amplitude (30 degrees), high-rate (10 Hz) forced roll motions were computed. The dynamics of the vortex breakdown motion was dramatically visualized by tracking the time-dependent motion of particles released near the delta wing apex. This numerical visualization is analogous to experimental smoke flow techniques. In one of the dynamic cases the breakdown was found to move off the wing, convected downwind of the trailing edge, and later reformed near the trailing edge through an instability of the vortex core. A damped free-to-roll motion was also computed by releasing the wing from rest at 40 degrees of roll. The wing went to the same trim point as in the experiment.
Chaderjian, Neal M.↗
Flight Test of the F/A-18 Active Aeroelastic Wing Airplane
A viewgraph presentation of flight tests performed on the F/A active aeroelastic wing airplane is shown. The topics include: 1) F/A-18 AAW Airplane; 2) F/A-18 AAW Control Surfaces; 3) Flight Test Background; 4) Roll Control Effectiveness Regions; 5) AAW Design Test Points; 6) AAW Phase I Test Maneuvers; 7) OBES Pitch Doublets; 8) OBES Roll Doublets; 9) AAW Aileron Flexibility; 10) Phase I - Lessons Learned; 11) Control Law Development and Verification & Validation Testing; 12) AAW Phase II RFCS Envelopes; 13) AAW 1-g Phase II Flight Test; 14) Region I - Subsonic 1-g Rolls; 15) Region I - Subsonic 1-g 360 Roll; 16) Region II - Supersonic 1-g Rolls; 17) Region II - Supersonic 1-g 360 Roll; 18) Region III - Subsonic 1-g Rolls; 19) Roll Axis HOS/LOS Comparison Region II - Supersonic (open-loop); 20) Roll Axis HOS/LOS Comparison Region II - Supersonic (closed-loop); 21) AAW Phase II Elevated-g Flight Test; 22) Region I - Subsonic 4-g RPO; and 23) Phase II - Lessons Learned
Voracek, David↗
Control system and method for tapered structure construction
A control system for forming a tapered structure includes a sensor providing feedback for a machine for forming a tapered structure including at least three rolls having at least one bend roll and at least two guide rolls. The guide rolls may include rollette banks having a plurality of rollettes. The machine may also include an adjustment mechanism to position at least one of the rolls, where a diameter of the tapered structure being formed is controlled by relative positions of the rolls. The machine may also include a joining element to join edges of a stock of material together as it is rolled through the rolls to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and to send a control signal based on the feedback to the adjustment mechanism for positioning at least one of the rolls.
Takata, Rosalind K.↗
The influence of thermomechanical treatment pathways on texture and mechanical properties in ARB Cu/Nb nanolaminates
Accumulative roll-bonded Cu/Nb nanolaminates (ARB Cu/Nb) possess high strength, thermal stability, and radiation tolerance arising from a high content of heterophase interfaces at fine layer thicknesses. These properties can be tailored by processing parameters used in the ARB Cu/Nb fabrication process, in which layer thickness, thermal history, and strain pathway determine the interface types and resultant properties found in the material. In this work, we subject ARB Cu/Nb to annealing, and then two different rolling pathways – one where rolling direction is held constant (longitudinal rolling, or LR), and one where rolling direction is rotated by 90º and held constant thereafter (cross rolling, or CR). Rolling is performed on ARB Cu/Nb over a targeted range of layer thicknesses from 193 to 25 nm and resultant bulk textures measured by neutron diffraction are correlated with mechanical properties measured by miniaturized tensile tests. The annealing procedure sharpens texture in both phases. We find that Cu mostly develops the same texture in LR and CR. In contrast, Nb develops a distinct texture along the CR pathway that is distinct from the LR texture. The composite texture of Cu/Nb is thus distinct between LR and CR pathways. This difference in texture development between Cu and Nb as a function of strain after change in rolling direction demonstrates the viability for deliberate pairing of Cu LR and Nb CR textures at a desired layer thickness. For mechanical properties, we find that differences in texture do not result in yield or flow stress differences above a layer thickness of 25 nm. Below a layer thickness of 25 nm, despite similar Taylor factors, yield and flow stress and are significantly different. In conclusion, this indicates texture only influences mechanical behavior at low layer thickness, where interface structure dominates mechanical properties.
36 MATERIALS SCIENCE↗
Imaging Complex Subsurface Structures for Geothermal Exploration at Pirouette Mountain and Eleven-Mile Canyon in Nevada
Accurate imaging of subsurface complex structures with faults is crucial for geothermal exploration because faults are generally the primary conduit of hydrothermal flow. It is very challenging to image geothermal exploration areas because of complex geologic structures with various faults and noisy surface seismic data with strong and coherent ground-roll noise. In addition, fracture zones and most geologic formations behave as anisotropic media for seismic-wave propagation. Properly suppressing ground-roll noise and accounting for subsurface anisotropic properties are essential for high-resolution imaging of subsurface structures and faults for geothermal exploration. We develop a novel wavenumber-adaptive bandpass filter to suppress the ground-roll noise without affecting useful seismic signals. This filter adaptively exploits both characteristics of the lower frequency and the smaller velocity of the ground-roll noise than those of the signals. Consequently, this filter can effectively differentiate the ground-roll noise from the signal. We use our novel filter to attenuate the ground-roll noise in seismic data along five survey lines acquired by the U.S. Navy Geothermal Program Office at Pirouette Mountain and Eleven-Mile Canyon in Nevada, United States. We then apply our novel anisotropic least-squares reverse-time migration algorithm to the resulting data for imaging subsurface structures at the Pirouette Mountain and Eleven-Mile Canyon geothermal exploration areas. The migration method employs an efficient implicit wavefield-separation scheme to reduce image artifacts and improve the image quality. Our results demonstrate that our wavenumber-adaptive bandpass filtering method successfully suppresses the strong and coherent ground-roll noise in the land seismic data, and our anisotropic least-squares reverse-time migration produces high-resolution subsurface images of Pirouette Mountain and Eleven-Mile Canyon, facilitating accurate fault interpretation for geothermal exploration.
15 GEOTHERMAL ENERGY↗
A preliminary look at the effects of coupled lateral modes on aircraft handling qualities
Analytic and six-degree-of-freedom motion base simulator studies have been conducted to better understand how the coupled roll-spiral and coupled roll-aileron actuator modes affect aircraft handling qualities. The results reported herein are preliminary and are subject to change until other aircraft and several more data points can be examined. The results obtained thus far indicate that when the roll-spiral coupled mode is brought about by unusual values of an aircraft's stability and control derivatives, the lateral-directional handling qualities will invariably be degraded. However, when the roll spiral coupling is brought about by a roll-rate command/roll-attitude hold stability and control augmentation system (SCAS), the requirements for satisfactory handling qualities can be correlated to the natural frequency and the damping of the coupled mode. Satisfactory handling qualities were also achieved when the lateral SCAS brought about a coupling of the roll mode with the aileron actuator mode. In this case, the pilot ratings indicate that the handling qualities may be correlated to the natural frequency of the coupled roll-aileron mode.
Ruflin, S. J.↗
Unsteady surface pressure measurements on a slender delta wing undergoing limit cycle wing rock
An experimental investigation of slender wing limit cycle motion known as wing rock was investigated using two unique experimental systems. Dynamic roll moment measurements and visualization data on the leading edge vortices were obtained using a free to roll apparatus that incorporates an airbearing spindle. In addition, both static and unsteady surface pressure data was measured on the top and bottom surfaces of the model. To obtain the unsteady surface pressure data a new computer controller drive system was developed to accurately reproduce the free to roll time history motions. The data from these experiments include, roll angle time histories, vortex trajectory data on the position of the vortices relative to the model's surface, and surface pressure measurements as a function of roll angle when the model is stationary or undergoing a wing rock motion. The roll time history data was numerically differentiated to determine the dynamic roll moment coefficient. An analysis of these data revealed that the primary mechanism for the limit cycle behavior was a time lag in the position of the vortices normal to the wing surface.
Arena, Andrew S., Jr.↗
Aerodynamic control of NASP-type vehicles through vortex manipulation. Volume 3: Wing rock experiments
Free-to-roll tests were conducted in water and wind tunnels in an effort to investigate the mechanisms of wing rock on a NASP-type vehicle. The configuration tested consisted of a highly-slender forebody and a 78 deg swept delta wing. In the water tunnel test, extensive flow visualization was performed and roll angle histories were obtained. In the wind tunnel test, the roll angle, forces and moments, and limited forebody and wing surface pressures were measured during the wing rock motion. A limit cycle oscillation was observed for angles of attack between 22 deg and 30 deg. In general, the experiments confirmed that the main flow phenomena responsible for the wing-body-tail wing rock are the interactions between the forebody and the wing vortices. The variation of roll acceleration (determined from the second derivative of the roll angle time history) with roll angle clearly slowed the energy balance necessary to sustain the limit cycle oscillation. Different means of suppressing wing rock by controlling the forebody vortices using small blowing jets were also explored. Steady blowing was found to be capable of suppressing wing rock, but significant vortex asymmetrices are created, causing the model to stop at a non-zero roll angle. On the other hand, alternating pulsed blowing on the left and right sides of the fore body was demonstrated to be a potentially effective means of suppressing wing rock and eliminating large asymmetric moments at high angles of attack.
Suarez, Carlos J.↗
Supersonic Aerodynamic Characteristics of a Low-Drag Aircraft Configuration having an Arrow Wing of Aspect Ratio 1.86 and a Body of Fineness Ratio 20
A free-flight rocket-propelled-model investigation was conducted at Mach numbers of 1.2 to 1.9 to determine the longitudinal and lateral aero-dynamic characteristics of a low-drag aircraft configuration. The model consisted of an aspect-ratio -1.86 arrow wing with 67.5 deg. leading-edge sweep and NACA 65A004 airfoil section and a triangular vertical tail with 60 deg. sweep and NACA 65A003 section in combination with a body of fineness ratio 20. Aerodynamic data in pitch, yaw, and roll were obtained from transient motions induced by small pulse rockets firing at intervals in the pitch and yaw directions. From the results of this brief aerodynamic investigation, it is observed that very slender body shapes can provide increased volumetric capacity with little or no increase in zero-lift drag and that body fineness ratios of the order of 20 should be considered in the design of long-range supersonic aircraft. The zero-lift drag and the drag-due-to-lift parameter of the test configuration varied linearly with Mach number. The maximum lift-drag ratio was 7.0 at a Mach number of 1.25 and decreased slightly to a value of 6.6 at a Mach number of 1.81. The optimum lift coefficient, normal-force-curve slope, lateral-force-curve slope, static stability in pitch and yaw, time to damp to one-half amplitude in pitch and yaw, the sum of the rotary damping derivatives in pitch and also in yaw, and the static rolling derivatives all decreased with an increase in Mach number. Values of certain rolling derivatives were obtained by application of the least-squares method to the differential equation of rolling motion. A comparison of the experimental and calculated total rolling-moment-coefficient variation during transient oscillations of the model indicated good agreement when the damping-in-roll contribution was included with the static rolling-moment terms.
Gillespie, Warren, Jr.↗
Analysis of Base Metal Microstructures and Mechanical Properties of a Single-Piece, Spin-Formed Forward Pressure Vessel Bulkhead
In 2012, a pathfinder forward pressure vessel bulkhead (FPVBH) for the Orion Multi-Purpose Crew Vehicle (MPCV) was fabricated using aluminum (Al) alloy 2219. The demonstration article was offered as a replacement for the baseline configuration, which at that time was a multi-piece welded construction using aluminum-lithium (Al-Li) alloy 2195. In 2014, the NASA Engineering and Safety Center (NESC) funded a Phase I effort to explore spin-forming as a manufacturing method to produce a complex-shaped, single-piece FPVBH for the crew module (CM) [1]. The primary focus of the NESC effort was to expand spin-forming technology to the fabrication of an Al-Li 2195 FPVBH. As a result, limited testing and analysis was performed on the original Al 2219 article. In this study, a sufficiently large plate of Al 2219 was not available for the fabrication of a FPVBH. Therefore, the forming blank comprised two plates (from different lots) butt welded together using a single friction stir weld. The welded forming blank was then spin formed into the FPVBH configuration and heat treated to the T62 temper. Mechanical property testing of the spin-formed 2219-T62 FPVBH revealed that the tensile properties were comparable to the Metallic Material Properties Development and Standardization (MMPDS) A-basis allowable for Al 2219-T6 wrought products. However, post-spin forming application of the standard heat treatment produced large, recrystallized grains in the material. The response varied within the two plates; one plate lot exhibited nearly complete recrystallization, while the other lot contained bands of recrystallization. Although no reduction in tensile properties was observed due to these microstructural variations, a more detailed investigation was recommended to better understand the effect of spin forming on the recrystallization mechanism and the impact on other material properties. The current study examined the microstructure and mechanical properties of the fully processed Al 2219-T62 FPVBH with emphasis on comparing differences between the two plates. Testing was limited to the cone region of the FPVBH. The two specific tasks in this study were: a) Characterization of the microstructure and mechanical properties in the two plates used in the FPVBH. b) Isolation of the impact of each step in the thermo-mechanical processing (TMP) sequence of the FPVBH on recrystallization and grain growth. Mechanical property testing sampled regions containing both large, recrystallized and small, unrecrystallized grains. Tensile strengths and elongations were equivalent in both regions and exceeded MMPDS A-basis allowables. Fracture toughness was equivalent in both regions and fracture morphology was typical of aluminum alloys. The fatigue precrack region of the fracture toughness specimens appeared more faceted in the recrystallized plate. This suggests that property testing that is more sensitive to grain size, such as fatigue crack growth rate and stress corrosion cracking, may be warranted. Alcoa reviewed the production records for the two plate lots and confirmed that composition of both plates was within the allowable range for Al 2219 and that plate processing steps were all performed within production limits. However, the Fe content was notably higher in the fully recrystallized plate, resulting in a greater volume fraction of large Fe-bearing inclusions and Al-Cu constituent particles. Alcoa did not provide details regarding plate processing variables for the two plate lots. It was surmised that deformation by hot rolling was the most accurate TMP simulation of commercial spin forming within a laboratory setting. Both hot rolling and spin forming comprise combinations of shear and compressive deformation. The through-thickness strain caused by hot rolling is symmetrical about the mid-plane, as the rollers contact both sides of the material. Shear strains are maximum at the inner and outer surfaces and trend toward zero at the mid-thickness. In contrast, spin forming utilizes a single roller on the outer surface, producing a gradient in shear stress through the thickness. Shear strains in spin-formed material are highest at the outer surface due to direct contact with the roller, and trend toward zero at the inner surface. Consequently, there will undoubtedly be some discrepancies in the mechanical response of hot-rolled and spin-formed products in the through-thickness direction. Interrupted TMP simulations were performed on remnant plate from the FPVBH forming blank in order to isolate the effects of a post-weld anneal, spin-forming deformation/thermal cycling, and solution heat treatment (SHT) on development of the recrystallized microstructures. Analysis confirmed that large, recrystallized grains formed exclusively during SHT and only after a certain deformation level was exceeded. Remnant plate from both lots that received thermal processing only did not exhibit recrystallization but exhibited fully recrystallized microstructures when processed by hot rolling. This indicates that (1) the level of deformation exceeded the critical level for recrystallization in both plates and (2) that the level of deformation during hot rolling was greater than that which accumulated during spin forming of the FPVBH. Comparison of the hot-rolled plate with the spin-formed material showed that the recrystallized grain size was larger in the FPVBH, providing further evidence that deformation levels were lower in the FPVBH. The most plausible explanation for the differing degrees of recrystallization in the two plates is particle stimulated nucleation (PSN) at the Fe-bearing inclusions and large Al-Cu constituent particles. In the plate with higher solute content, the greater volume fraction of these particles reduces the deformation level required to promote recrystallization. During spin forming the critical deformation level was likely exceeded for the higher Fe content plate resulting in a fully recrystallized microstructure. The lower Fe content plate developed a microstructure that exhibited bands of recrystallization due to the combination of a non-uniform distribution of particles and deformation. The critical deformation required for recrystallization was likely only exceeded during spin forming in regions of higher particle content. While there were differences in Fe content between these lots of Al 2219 plate, the composition of both was within defined alloy limits and Alcoa reported no anomalies during plate production. The observed differences in recrystallization after spin forming may reflect the inherent variability between these two lots of plate. The spin-forming vendor, Spincraft, reported that similar variations in recrystallized microstructures have been observed during examination of multiple spin-forming trials of a different 2xxx series aluminum alloy. Hence, tighter chemical specification limits on impurity levels in Al 2219 plate may help ensure uniform, predictable microstructures. Finally, the tensile and fracture toughness properties were not affected by the microstructural variations noted.
single-piece↗