Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “ORION”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,369 records · Page 76
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

MLAS and LAS: Project Comparison of Lessons Learned

The development of new and safer manned space vehicles is a top priority at NASA. Recently two different approaches of how to accomplish this mission of keeping astronauts safe was successfully demonstrated. With work already underway on an Apollo-like launch abort system for the Orion Crew Exploration Vehicle (CEV), an alternative design concept named the Max Launch Abort System, or MLAS, was developed as a parallel effort. The Orion system, managed by the Constellation office, is based on the design of a single solid launch abort motor in a tower positioned above the capsule. The MLAS design takes a different approach placing the solid launch abort motor underneath the capsule. This effort was led by the NASA Engineering and Safety Center (NESC). Both escape systems were designed with the Ares I Rocket as the launch vehicle and had the same primary requirement to safely propel a crew module away from any emergency event either on the launch pad or during accent. Beyond these two parameters, there was little else in common between the two projects, except that they both concluded in successful launches that will further promote the development of crew launch abort systems. This presentation will compare both projects from the standpoint of technical requirements; program management and flight test objectives and highlight the synergistic lessons learned by two engineers who worked on each program.

Dittemore, Gary↗
NASA NTRS2011

Comparison of Two Recent Launch Abort Platforms

The development of new and safer manned space vehicles is a top priority at NASA. Recently two different approaches of how to accomplish this mission of keeping astronauts safe was successfully demonstrated. With work already underway on an Apollo-like launch abort system for the Orion Crew Exploration Vehicle (CEV), an alternative design concept named the Max Launch Abort System, or MLAS, was developed as a parallel effort. The Orion system, managed by the Constellation office, is based on the design of a single solid launch abort motor in a tower positioned above the capsule. The MLAS design takes a different approach placing the solid launch abort motor underneath the capsule. This effort was led by the NASA Engineering and Safety Center (NESC). Both escape systems were designed with the Ares I Rocket as the launch vehicle and had the same primary requirement to safely propel a crew module away from any emergency event either on the launch pad or during accent. Beyond these two parameters, there was little else in common between the two projects, except that they both concluded in successful launches that will further promote the development of crew launch abort systems. A comparison of these projects from the standpoint of technical requirements; program management and flight test objectives will be done to highlight the synergistic lessons learned by two engineers who worked on each program. This comparison will demonstrate how the scope of the project architecture and management involvement in innovation should be tailored to meet the specific needs of the system under development.

Dittemore, Gary D.↗
NASA NTRS2011

Space Shuttle Guidance, Navigation, and Rendezvous Knowledge Capture Reports

This document is a catalog and readers guide to lessons learned, experience, and technical history reports, as well as compilation volumes prepared by United Space Alliance personnel for the NASA/Johnson Space Center (JSC) Flight Dynamics Division.1 It is intended to make it easier for future generations of engineers to locate knowledge capture documentation from the Shuttle Program. The first chapter covers observations on documentation quality and research challenges encountered during the Space Shuttle and Orion programs. The second chapter covers the knowledge capture approach used to create many of the reports covered in this document. These chapters are intended to provide future flight programs with insight that could be used to formulate knowledge capture and management strategies. The following chapters contain descriptions of each knowledge capture report. The majority of the reports concern the Space Shuttle. Three are included that were written in support of the Orion Program. Most of the reports were written from the years 2001 to 2011. Lessons learned reports concern primarily the shuttle Global Positioning System (GPS) upgrade and the knowledge capture process. Experience reports on navigation and rendezvous provide examples of how challenges were overcome and how best practices were identified and applied. Some reports are of a more technical history nature covering navigation and rendezvous. They provide an overview of mission activities and the evolution of operations concepts and trajectory design. The lessons learned, experience, and history reports would be considered secondary sources by historians and archivists.

John L Goodman↗
NASA NTRS2011

Tool for Rapid Analysis of Monte Carlo Simulations

Designing a spacecraft, or any other complex engineering system, requires extensive simulation and analysis work. Oftentimes, the large amounts of simulation data generated are very di cult and time consuming to analyze, with the added risk of overlooking potentially critical problems in the design. The authors have developed a generic data analysis tool that can quickly sort through large data sets and point an analyst to the areas in the data set that cause specific types of failures. The Tool for Rapid Analysis of Monte Carlo simulations (TRAM) has been used in recent design and analysis work for the Orion vehicle, greatly decreasing the time it takes to evaluate performance requirements. A previous version of this tool was developed to automatically identify driving design variables in Monte Carlo data sets. This paper describes a new, parallel version, of TRAM implemented on a graphical processing unit, and presents analysis results for NASA's Orion Monte Carlo data to demonstrate its capabilities.

Restrepo, Carolina↗
NASA NTRS2011

Constitutive Soil Properties for Mason Sand and Kennedy Space Center

Accurate soil models are required for numerical simulations of land landings for the Orion Crew Exploration Vehicle (CEV). This report provides constitutive material models for two soil conditions at Kennedy Space Center (KSC) and four conditions of Mason Sand. The Mason Sand is the test sand for LaRC s drop tests and swing tests of the Orion. The soil models are based on mechanical and compressive behavior observed during geotechnical laboratory testing of remolded soil samples. The test specimens were reconstituted to measured in situ density and moisture content. Tests included: triaxial compression, hydrostatic compression, and uniaxial strain. A fit to the triaxial test results defines the strength envelope. Hydrostatic and uniaxial tests define the compressibility. The constitutive properties are presented in the format of LSDYNA Material Model 5: Soil and Foam. However, the laboratory test data provided can be used to construct other material models. The soil models are intended to be specific to the soil conditions they were tested at. The two KSC models represent two conditions at KSC: low density dry sand and high density in-situ moisture sand. The Mason Sand model was tested at four conditions which encompass measured conditions at LaRC s drop test site.

Thomas, Michael A.↗
NASA NTRS2011

Launch Vehicle Demonstrator Using Shuttle Assets

The Marshall Space Flight Center Advanced Concepts Office (ACO) has the leading role for NASA s preliminary conceptual launch vehicle design and performance analysis. Over the past several years the ACO Earth-to-Orbit Team has evaluated thousands of launch vehicle concept variations for a multitude of studies including agency-wide efforts such as the Exploration Systems Architecture Study (ESAS), Constellation, Heavy Lift Launch Vehicle (HLLV), Heavy Lift Propulsion Technology (HLPT), Human Exploration Framework Team (HEFT), and Space Launch System (SLS). NASA plans to continue human space exploration and space station utilization. Launch vehicles used for heavy lift cargo and crew will be needed. One of the current leading concepts for future heavy lift capability is an inline one and a half stage concept using solid rocket boosters (SRB) and based on current Shuttle technology and elements. Potentially, the quickest and most cost-effective path towards an operational vehicle of this configuration is to make use of a demonstrator vehicle fabricated from existing shuttle assets and relying upon the existing STS launch infrastructure. Such a demonstrator would yield valuable proof-of-concept data and would provide a working test platform allowing for validated systems integration. Using shuttle hardware such as existing RS-25D engines and partial MPS, propellant tanks derived from the External Tank (ET) design and tooling, and four-segment SRB s could reduce the associated upfront development costs and schedule when compared to a concept that would rely on new propulsion technology and engine designs. There are potentially several other additional benefits to this demonstrator concept. Since a concept of this type would be based on man-rated flight proven hardware components, this demonstrator has the potential to evolve into the first iteration of heavy lift crew or cargo and serve as a baseline for block upgrades. This vehicle could also serve as a demonstration and test platform for the Orion Program. Critical spacecraft systems, re-entry and recovery systems, and launch abort systems of Orion could also be demonstrated in early test flights of the launch vehicle demo. Furthermore, an early demonstrator of this type would provide a stop-gap for retaining critical human capital and infrastructure while affording the current emerging generation of young engineers opportunity to work with and capture lessons learned from existing STS program offices and personnel, who were integral in the design and development of the Space Shuttle before these resources are no longer available. The objective of this study is to define candidate launch vehicle demonstration concepts that are based on Space Shuttle assets and determine their performance capabilities and how these demonstration vehicles could evolve to a heavy lift capability to low earth orbit.

Threet, Grady E., Jr.↗
NASA NTRS2011

Ground Vibration Testing Options for Space Launch Vehicles

New NASA launch vehicles will require development of robust systems in a fiscally-constrained environment. NASA, Department of Defense (DoD), and commercial space companies routinely conduct ground vibration tests as an essential part of math model validation and launch vehicle certification. Although ground vibration testing must be a part of the integrated test planning process, more affordable approaches must also be considered. A study evaluated several ground vibration test options for the NASA Constellation Program flight test vehicles, Orion-1 and Orion-2, which concluded that more affordable ground vibration test options are available. The motivation for ground vibration testing is supported by historical examples from NASA and DoD. The approach used in the present study employed surveys of ground vibration test subject-matter experts that provided data to qualitatively rank six test options. Twenty-five experts from NASA, DoD, and industry provided scoring and comments for this study. The current study determined that both element-level modal tests and integrated vehicle modal tests have technical merits. Both have been successful in validating structural dynamic math models of launch vehicles. However, element-level testing has less overall cost and schedule risk as compared to integrated vehicle testing. Future NASA launch vehicle development programs should anticipate that some structural dynamics testing will be necessary. Analysis alone will be inadequate to certify a crew-capable launch vehicle. At a minimum, component and element structural dynamic tests are recommended for new vehicle elements. Three viable structural dynamic test options were identified. Modal testing of the new vehicle elements and an integrated vehicle test on the mobile launcher provided the optimal trade between technical, cost, and schedule.

Patterson, Alan↗
NASA NTRS2011

Optical Property Requirements for Glasses, Ceramics and Plastics in Spacecraft Window Systems

This is a preliminary draft of a standard published by the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) that is intended to provide uniform window optical design requirements in support of the development of human-rated spaceflight hardware. The material covered in this standard is based on data from extensive testing by the Advanced Sensing and Optical Measurement Branch at NASA Langley Research Center, and compiled into requirements format by the NASA JSC Structural Engineering Division. At the time of this initial document release, a broader technical community has not reviewed this standard. The technical content of this standard is primarily based on the Constellation Program Orion Crew Exploration Vehicle Window Optical Properties Requirements, CxP 72407, Baseline. Unlike other optical requirements documents available for human rated spacecraft, this document includes requirements that ensure functionality for windows that contain glass/ceramic and/or plastic window substrate materials. These requirements were derived by measuring the optical properties of fused silica and aluminosilicate glass window assemblies and ensuring that the performance of any window assembly that includes a plastic pane or panes will meet the performance level of the all-glass assemblies. The resulting requirements are based upon the performance and parameter metrology testing of a variety of materials, including glass, transparent ceramics, acrylics, and polycarbonates. In general, these requirements are minimum specifications for each optical parameter in order to achieve the function specified for each functional category, A through D. Because acrylic materials perform at a higher level than polycarbonates in the optics regime, and CxP/Orion is planning to use acrylic in the Orion spacecraft, these requirements are based heavily on metrology from that material. As a result, two of the current Category D requirements for plastics are cited in such a way that will result in the screening out of polycarbonates. It is acknowledged that many polycarbonates can perform the functions of Category D, such as piloting and imagery with lens with apertures up to 25mm, without performance issues. Therefore, this forward warns users that certain requirements, such as birefringence and wavefront, for Category D plastics need to be revised to allow those polycarbonates that perform adequately in Category D to be accepted, while at the same time, screen out those materials that do not perform up to par. At the time of document release, the requirements in question have been identified by a TBD beside the proposed requirement criteria (which is based upon acrylic performance). Vehicles that are designed with acrylic materials for windowpanes are encouraged to use the values presented in this document for all requirements, in order to ensure adequate optical performance.

Lynda R Estes↗
NASA NTRS2011

Wallops Low Elevation Link Analysis for the Constellation Launch/Ascent Links

To execute the President's Vision for Space Exploration, the Constellation Program (CxP) was formed to build the next generation spacecraft Orion and launch vehicles Ares, to transport human and cargo to International Space Station (ISS), moon, and Mars. This paper focuses on the detailed link analysis for Orion/Ares s launch and ascent links with Wallops 11.3m antenna (1) Orion's Dissimilar Voice link: 10.24 Kbps, 2-way (2) Ares Developmental Flight Instrument link, 20 Mbps, downlink. Three launch trajectories are considered: TD7-E, F (Feb), and G (Aug). In certain launch scenarios, the critical events of main engine cutoff (MECO) and Separation occur during the low elevation regime of WFF s downrange -- less than 5 degree elevation angle. The goal of the study is to access if there is enough link margins for WFF to track the DV and DFI links.

Constellation↗
NASA NTRS2011

2011 Ground Testing Highlights Article

Two tests supporting development of the launch abort system for the Orion MultiPurpose Crew Vehicle were run in the NASA Ames Unitary Plan wind tunnel last year. The first test used a fully metric model to examine the stability and controllability of the Launch Abort Vehicle during potential abort scenarios for Mach numbers ranging from 0.3 to 2.5. The aerodynamic effects of the Abort Motor and Attitude Control Motor plumes were simulated using high-pressure air flowing through independent paths. The aerodynamic effects of the proximity to the launch vehicle during the early moments of an abort were simulated with a remotely actuated Service Module that allowed the position relative to the Crew Module to be varied appropriately. The second test simulated the acoustic environment around the Launch Abort Vehicle caused by the plumes from the 400,000-pound thrust, solid-fueled Abort Motor. To obtain the proper acoustic characteristics of the hot rocket plumes for the flight vehicle, heated Helium was used. A custom Helium supply system was developed for the test consisting of 2 jumbo high-pressure Helium trailers, a twelve-tube accumulator, and a 13MW gas-fired heater borrowed from the Propulsion Simulation Laboratory at NASA Glenn Research Center. The test provided fluctuating surface pressure measurements at over 200 points on the vehicle surface that have now been used to define the ground-testing requirements for the Orion Launch Abort Vehicle.

Ross, James C.↗
NASA NTRS2012

High-Data-Rate Quadrax Cable Microwave Characterization at the NASA Glenn Structural Dynamics Laboratory

An experiment was performed to determine the degradation in the bit-error-rate (BER) in the high-data-rate cables chosen for the Orion Service Module due to extreme launch conditions of vibrations with a magnitude of 60g. The cable type chosen for the Orion Service Module was no. 8 quadrax cable. The increase in electrical noise induced on these no. 8 quadrax cables was measured at the NASA Glenn vibration facility in the Structural Dynamics Laboratory. The intensity of the vibrations was set at 32g, which was the maximum available level at the facility. The cable lengths used during measurements were 1, 4, and 8 m. The noise measurements were done in an analog fashion using a performance network analyzer (PNA) by recording the standard deviation of the transmission scattering parameter S(sub 21) over the frequency range of 100 to 900 MHz. The standard deviation of S(sub 210 was measured before, during, and after the vibration of the cables at the vibration facility. We observed an increase in noise by a factor of 2 to 6. From these measurements we estimated the increase expected in the BER for a cable length of 25 m and concluded that these findings are large enough that the noise increase due to vibration must be taken in to account for the design of the communication system for a BER of 10(exp -8).

Theofylaktos, Onoufrios↗
NASA NTRS2012

Postures and Motions Library Development for Verification of Ground Crew Human Systems Integration Requirements

Spacecraft and launch vehicle ground processing activities require a variety of unique human activities. These activities are being documented in a Primitive motion capture library. The Library will be used by the human factors engineering in the future to infuse real to life human activities into the CAD models to verify ground systems human factors requirements. As the Primitive models are being developed for the library the project has selected several current human factors issues to be addressed for the SLS and Orion launch systems. This paper explains how the Motion Capture of unique ground systems activities are being used to verify the human factors analysis requirements for ground system used to process the STS and Orion vehicles, and how the primitive models will be applied to future spacecraft and launch vehicle processing.

Jackson, Mariea Dunn↗
NASA NTRS2013

An Alternative Flight Software Trigger Paradigm: Applying Multivariate Logistic Regression to Sense Trigger Conditions using Inaccurate or Scarce Information

In late 2014, NASA will fly the Orion capsule on a Delta IV-Heavy rocket for the Exploration Flight Test-1 (EFT-1) mission. For EFT-1, the Orion capsule will be flying with a new GPS receiver and new navigation software. Given the experimental nature of the flight, the flight software must be robust to the loss of GPS measurements. Once the high-speed entry is complete, the drogue parachutes must be deployed within the proper conditions to stabilize the vehicle prior to deploying the main parachutes. When GPS is available in nominal operations, the vehicle will deploy the drogue parachutes based on an altitude trigger. However, when GPS is unavailable, the navigated altitude errors become excessively large, driving the need for a backup barometric altimeter. In order to increase overall robustness, the vehicle also has an alternate method of triggering the drogue parachute deployment based on planet-relative velocity if both the GPS and the barometric altimeter fail. However, this velocity-based trigger results in large altitude errors relative to the targeted altitude. Motivated by this challenge, this paper demonstrates how logistic regression may be employed to automatically generate robust triggers based on statistical analysis. Logistic regression is used as a ground processor pre-flight to develop a classifier. The classifier would then be implemented in flight software and executed in real-time. This technique offers excellent performance even in the face of highly inaccurate measurements. Although the logistic regression-based trigger approach will not be implemented within EFT-1 flight software, the methodology can be carried forward for future missions and vehicles.

Smith, Kelly M.↗
NASA NTRS2013

An Alternative Flight Software Trigger Paradigm: Applying Multivariate Logistic Regression to Sense Trigger Conditions Using Inaccurate or Scarce Information

In late 2014, NASA will fly the Orion capsule on a Delta IV-Heavy rocket for the Exploration Flight Test-1 (EFT-1) mission. For EFT-1, the Orion capsule will be flying with a new GPS receiver and new navigation software. Given the experimental nature of the flight, the flight software must be robust to the loss of GPS measurements. Once the high-speed entry is complete, the drogue parachutes must be deployed within the proper conditions to stabilize the vehicle prior to deploying the main parachutes. When GPS is available in nominal operations, the vehicle will deploy the drogue parachutes based on an altitude trigger. However, when GPS is unavailable, the navigated altitude errors become excessively large, driving the need for a backup barometric altimeter to improve altitude knowledge. In order to increase overall robustness, the vehicle also has an alternate method of triggering the parachute deployment sequence based on planet-relative velocity if both the GPS and the barometric altimeter fail. However, this backup trigger results in large altitude errors relative to the targeted altitude. Motivated by this challenge, this paper demonstrates how logistic regression may be employed to semi-automatically generate robust triggers based on statistical analysis. Logistic regression is used as a ground processor pre-flight to develop a statistical classifier. The classifier would then be implemented in flight software and executed in real-time. This technique offers improved performance even in the face of highly inaccurate measurements. Although the logistic regression-based trigger approach will not be implemented within EFT-1 flight software, the methodology can be carried forward for future missions and vehicles.

Smith, Kelly M.↗
NASA NTRS2013

An Alternative Flight Software Paradigm: Applying Multivariate Logistic Regression to Sense Trigger Conditions using Inaccurate or Scarce Information

In late 2014, NASA will fly the Orion capsule on a Delta IV-Heavy rocket for the Exploration Flight Test-1 (EFT-1) mission. For EFT-1, the Orion capsule will be flying with a new GPS receiver and new navigation software. Given the experimental nature of the flight, the flight software must be robust to the loss of GPS measurements. Once the high-speed entry is complete, the drogue parachutes must be deployed within the proper conditions to stabilize the vehicle prior to deploying the main parachutes. When GPS is available in nominal operations, the vehicle will deploy the drogue parachutes based on an altitude trigger. However, when GPS is unavailable, the navigated altitude errors become excessively large, driving the need for a backup barometric altimeter to improve altitude knowledge. In order to increase overall robustness, the vehicle also has an alternate method of triggering the parachute deployment sequence based on planet-relative velocity if both the GPS and the barometric altimeter fail. However, this backup trigger results in large altitude errors relative to the targeted altitude. Motivated by this challenge, this paper demonstrates how logistic regression may be employed to semi-automatically generate robust triggers based on statistical analysis. Logistic regression is used as a ground processor pre-flight to develop a statistical classifier. The classifier would then be implemented in flight software and executed in real-time. This technique offers improved performance even in the face of highly inaccurate measurements. Although the logistic regression-based trigger approach will not be implemented within EFT-1 flight software, the methodology can be carried forward for future missions and vehicles

Smith, Kelly↗
NASA NTRS2013

Thermal Protection and Control

During all phases of a spacecraft's mission, a Thermal Protection System (TPS) is needed to protect the vehicle and structure from extreme temperatures and heating. When designing TPS, low weight and cost while ensuring the protection of the vehicle is highly desired. There are two main types of TPS, ablative and reusable. The Apollo missions needed ablators due to the high heat loads from lunar reentry. However, when the desire for a reusable space vehicle emerged, the resultant_ Space Shuttle program propelled a push for the development of reusable TPS. With the growth of reqsable TPS, the need for ablators declined, triggering a drop off of the ablator industry. As a result, the expertise was not heavily maintained within NASA or the industry. When the Orion Program initiated a few years back, a need. for an ablator reemerged. Yet, due to of the lack of industry capability, redeveloping the ablator material took several years and came at a high cost. As NASA looks towards the future with both the Orion and Commercial Crew Programs, a need to preserve reusable, ablative, and other TPS technologies is essential. Research of the different TPS materials alongside their properties, capabilities, and manufacturing process was performed, and the benefits of the materials were analyzed alongside the future of TPS. Knowledge of the different technologies has the ability to help us know what expertise to maintain and ensure a lack in the industry does not occur again.

Greene, Effie E.↗
NASA NTRS2013

NASA's Space Launch System: Moving Toward the Launch Pad

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human space flight and scientific missions beyond Earth orbit. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Supporting Orion's first autonomous flight to lunar orbit and back in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown, via an upgrade approach that will provide building blocks for future space exploration and development. NASA is working to develop this new capability in an austere economic climate, a fact which has inspired the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history. This paper will summarize the planned capabilities of the vehicle, the progress the SLS program has made in the 2 years since the Agency formally announced its architecture in September 2011, and the path the program is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130-t lift capability. The paper will explain how, to meet the challenge of a flat funding curve, an architecture was chosen which combines the use and enhancement of legacy systems and technology with strategic new development projects that will evolve the capabilities of the launch vehicle. This approach reduces the time and cost of delivering the initial 70 t Block 1 vehicle, and reduces the number of parallel development investments required to deliver the evolved version of the vehicle. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware and the record-breaking testing of the J-2X engine, to life-cycle milestones such as the vehicle's Preliminary Design Review. The paper will also discuss the remaining challenges in both delivering the 70 t vehicle and in evolving its capabilities to the 130 t vehicle, and how the program plans to accomplish these goals. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration

Creech, Stephen D.↗
NASA NTRS2013

Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication in support of the 2014 launch of the Orion MPCV.

Alcorn, John↗