NASA has partnered with Lockheed Martin Space Systems in Denver, Colo., and MT Aerospace in Augsburg, Germany, to successfully manufacture the first full-scale friction stir welded and spun formed tank dome designed for use in large liquid propellant tanks.
The NASA and Lockheed Martin team traveled to Germany to witness the first successful aerospace application of two separate manufacturing processes: friction stir welding, a solid-state joining process, and spin forming, a metal working process used to form symmetric parts.
The twin processes were used by MT Aerospace to produce an 18-foot-diameter tank dome using high-strength 2195 aluminum-lithium. The diameter of this development dome matches the tank dimensions of the upper stage of the ARES I launch vehicle under development by NASA, as well as the central stage of the European Ariane V launcher.
"This new manufacturing technology allows us to use a thinner, high-strength alloy that will reduce the weight of future liquid propellant tanks by 25 percent, compared to current tank designs that use a lower-strength aluminum alloy that weighs more," said Louis Lollar, project lead for the Friction Stir Weld Spun Form Dome Project at NASA's Marshall Space Flight Center in Huntsville, Ala.
The concave net shape spin forming process, patented by MT Aerospace, drastically simplifies the manufacturing of large tank domes and reduces cost by eliminating manufacturing steps, such as machining and assembly welding, that are required when manufacturing traditional gore panel - a pie-shaped section of the tank dome --construction domes.
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