NASA Technical Reports Server (NTRS) 20160006928: Innovative Forming of Advanced Metallics PDF
Preview NASA Technical Reports Server (NTRS) 20160006928: Innovative Forming of Advanced Metallics
LLaanngglleeyy RReesseeaarrcchh CCeenntteerr LaRC Innovative Forming of Advanced Metallics John Wagner and Marcia Domack NASA- Langley Research Center Hampton, Virginia January 2015 NASA Field Centers LLaanngglleeyy RReesseeaarrcchh CCeenntteerr AAmmeess RReesseeaarrcchh CCeenntteerr GGlleennnn RReesseeaarrcchh CCeenntteerr CCaappaabbiilliittiieess GGooddddaarrdd SSppaaccee FFlliigghhtt CCeenntteerr JJeett PPrrooppuullssiioonn DDiissttrriibbuutteedd LLaabboorraattoorryy AAggeennccyywwiiddee LLaanngglleeyy RReesseeaarrcchh CCeenntteerr DDrryyddeenn FFlliigghhtt RReesseeaarrcchh CCeenntteerr KKeennnneeddyy SSppaaccee CCeenntteerr MMaarrsshhaallll SSppaaccee JJoohhnnssoonn SSppaaccee CCeenntteerr FFlliigghhtt CCeenntteerr NASA Langley Research Center LLaanngglleeyy RReesseeaarrcchh CCeenntteerr Delivering on Today’s Commitments… Creating Tomorrow’s Opportunities. www.nasa.gov NASA Langley Core Competencies LLaanngglleeyy RReesseeaarrcchh CCeenntteerr Aerospace Systems Analysis Aerosciences Research for Flight in All Atmospheres Entry, Descent & Landing Characterization of all Atmospheres Materials & Structures (Lasers & LIDAR) Materials & Structures LLaanngglleeyy RReesseeaarrcchh CCeenntteerr Materials Synthesis Durability & & Processing Damage Tolerance Computational Materials Impact & Landing Design Dynamics Nanostructured Materials Structural Concepts Advanced Materials and Processing Branch LLaanngglleeyy RReesseeaarrcchh CCeenntteerr Materials Design Innovative Materials Processing Materials Testing O O CN (N O N O O ) O O Design Processing CNT Characterization Nanocomposite Modeling Advanced Material Systems Materials for Extreme Environments 2 mm Near Net Shape Manufacturing of Al & Al-Li Alloys for Launch Vehicle Structures LLaanngglleeyy RReesseeaarrcchh CCeenntteerr Roll Forging Shear Forming -Adapter Rings Friction Stir Welding -Seamless Cryotank -Butt & Lap Joints Section Spin Forming -Cryotank Dome S• Reduced Material Scrap Rate T • Lower Cost, Enhanced Performance I Integrally Stiffened Extrusion F E• Increased Reliability -Seamless Cryotank Section N • Reduced Part Count E B• Reduced Assembly Time Motivation and Background LLaanngglleeyy RReesseeaarrcchh CCeenntteerr • Majority of launch vehicle cryotanks and dry bay structures fabricated using Al alloys and fabrication technologies developed in the 1950’s • Opportunities exist for utilizing new and revolutionary metal forming techniques to significantly impact cost, weight and safety • Near net shape forming has the potential to reduce metal scrap rate (machining chips) in the production of launch vehicle structures from the current rate of 90% to 5% • Al- Li alloys are ~ 10 % lighter and exhibit higher strength and modulus than current 2219 Al cryotank material • Increased safety and reduced weight though the elimination of welds (defects) and weld land (ET has 30,000 inches of welds) Cryogenic Tank Dome Manufacturing Multi-Piece Welded Gore Construction vs. Spin Forming LLaanngglleeyy RReesseeaarrcchh CCeenntteerr Traditional Approach Plate Gore Mandrel Dome Gore Panel Dome Gores Welded Gore Assy. Dome Developmental Approach Plate FSW dome blank Spin forming process Spun Formed Dome Inspection of Partially Formed Dome LLaanngglleeyy RReesseeaarrcchh CCeenntteerr DSC_0043.jpg
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