Design of a welded joint for robotic, on-orbit assembly of space trusses

In the future, some spacecraft will be so large that they must be assembled on-orbit. These spacecraft will be used for such tasks as manned missions to Mars or used as orbiting platforms for monitoring the Earth or observing the universe. Some large spacecraft will probably consist of planar truss structures to which will be attached special purpose, self-contained modules. The modules will most likely be taken to orbit fully outfitted and ready for use in heavy-lift launch vehicles. The truss members will also similarly be taken to orbit, but most unassembled. The truss structures will need to be assembled robotically because of the high costs and risks of extra-vehicular activities. Some missions will involve very large loads. To date, very few structures of any kind have been constructed in space. Two relatively simple trusses were assembled in the Space Shuttle bay in late 1985. Here the development of a design of a welded joint for on-orbit, robotic truss assembly is described. Mechanical joints for this application have been considered previously. Welded joints have the advantage of allowing the truss members to carry fluids for active cooling or other purposes. In addition, welded joints can be made more efficient structurally than mechanical joints. Also, welded joints require little maintenance (will not shake loose), and have no slop which would cause the structure to shudder under load reversal. The disadvantages of welded joints are that a more sophisticated assembly robot is required, weld flaws may be difficult to detect on-orbit, the welding process is hazardous, and welding introduces contamination to the environment. In addition, welded joints provide less structural damping than do mechanical joints. Welding on-orbit was first investigated aboard a Soyuz-6 mission in 1969 and then during a Skylab electron beam welding experiment in 1973. A hand held electron beam welding apparatus is currently being prepared for use on the MIR space station. Presently, Marshall Space Flight Center is evaluating processes appropriate for on-orbit welding. A low gravity environment has been found to have very minor effects on the welding processes appropriate for this application. This is based on tests run on-orbit as well as low gravity environments achieved by flying aircraft in parabolic trajectories. It appears that a modified form of gas tungsten arc welding (GTAW) will be most appropriate for welding together structures on-oribt. The process has been modified to work in a vacuum by providing gas to the arc zone by means of a hollow tungsten electrode with special shielding. A commercial tube welding head has been successfully modified for use on-orbit with a gas leakage rate of approximately 2.5 liters/min. To develop as realistic a joint as possible, a specific truss structure was selected on which to base the design. The structure considered was based on the 120 foot diameter aerobrake tetrahedral truss structure. The truss members were assumed to consist of graphite/epoxy tubes. Also, it was assumed that the nodes were constructed of 2219-T87 aluminum alloy. The magnitude of the member load assumed for design purposes was 100 kips

Sunspot: A program to model the behavior of hypervelocity impact damaged multilayer insulation in the Sunspot thermal vacuum chamber of Marshall Space Flight Center

The development of a computer program to predict the degradation of the insulating capabilities of the multilayer insulation (MLI) blanket of Space Station Freedom due to a hypervelocity impact with a space debris particle is described. A finite difference scheme is used for the calculations. The computer program was written in Microsoft BASIC. Also described is a test program that was undertaken to validate the numerical model. Twelve MLI specimens were impacted at hypervelocities with simulated debris particles using a light gas gun at Marshall Space Flight Center. The impact-damaged MLI specimens were then tested for insulating capability in the space environment of the Sunspot thermal vacuum chamber at MSFC. Two undamaged MLI specimens were also tested for comparison with the test results of the damaged specimens. The numerical model was found to adequately predict behavior of the MLI specimens in the Sunspot chamber. A parameter, called diameter ratio, was developed to relate the nominal MLI impact damage to the apparent (for thermal analysis purposes) impact damage based on the hypervelocity impact conditions of a specimen

Empirical predictions of hypervelocity impact damage to the space station

A family of user-friendly, DOS PC based, Microsoft BASIC programs written to provide spacecraft designers with empirical predictions of space debris damage to orbiting spacecraft is described. The spacecraft wall configuration is assumed to consist of multilayer insulation (MLI) placed between a Whipple style bumper and the pressure wall. Predictions are based on data sets of experimental results obtained from simulating debris impacts on spacecraft using light gas guns on Earth. A module of the program facilitates the creation of the data base of experimental results that are used by the damage prediction modules of the code. The user has the choice of three different prediction modules to predict damage to the bumper, the MLI, and the pressure wall. One prediction module is based on fitting low order polynomials through subsets of the experimental data. Another prediction module fits functions based on nondimensional parameters through the data. The last prediction technique is a unique approach that is based on weighting the experimental data according to the distance from the design point

An efficient frequency response solution for nonproportionally damped systems

A method is presented to accurately and economically calculate steady state frequency responses based on the analysis of large finite element models with nonproportional damping effects. The new method is a hybrid of the traditional nonproportional and proportional damping solution methods. It captures the advantages of each computational approach without the burden of their respective shortcomings, as demonstrated with comparative analysis performed on a large finite element model

Charge-equilibrium and radiation of low-energy cosmic rays passing through interstellar medium

The charge equilibrium and radiation of an oxygen and an iron beam in the MeV per nucleon energy range, representing a typical beam of low-energy cosmic rays passing through the interstellar medium, is considered. Electron loss of the beam has been taken into account by means of the First Born approximation allowing for the target atom to remain unexcited, or to be excited to all possible states. Electron capture cross sections have been calculated by means of the scaled Oppenheimer-Brinkman-Kramers approximation, taking into account all atomic shells of the target atoms. Radiation of the beam due to electron capture into the excited states of the ion, collisional excitation and collisional inner-shell ionization of the ions has been considered. Effective X-ray production cross sections and multiplicities for the most energetic X-ray lines emitted by the Fe and O beams have been calculated

Design of a welded joint for robotic, on-orbit assembly of space trusses

A preliminary design for a weldable truss joint for on-orbit assembly of large space structures is described. The joint was designed for ease of assembly, for structural efficiency, and to allow passage of fluid (for active cooling or other purposes) along the member through the joint. The truss members were assumed to consist of graphite/epoxy tubes to which were bonded 2219-T87 aluminum alloy end fittings for welding on-orbit to truss nodes of the same alloy. A modified form of gas tungsten arc welding was assumed to be the welding process. The joint was designed to withstand the thermal and structural loading associated with a 120-ft diameter tetrahedral truss intended as an aerobrake for a mission to Mars

MLIBlast: A program to empirically predict hypervelocity impact damage to the Space Station

MLIBlast is described, which consists of a number of DOC PC based MIcrosoft BASIC program modules written to provide spacecraft designers with empirical predictions of space debris damage to orbiting spacecraft. The Spacecraft wall configuration is assumed to consist of multilayer insulation (MLI) placed between a Whipple style bumper and a pressure wall. Predictions are based on data sets of experimental results obtained from simulating debris impact on spacecraft. One module of MLIBlast facilitates creation of the data base of experimental results that is used by the damage prediction modules of the code. The user has a choice of three different prediction modules to predict damage to the bumper, the MLI, and the pressure wall

Quantum phase transitions and decoupling of magnetic sublattices in the quasi-two-dimensional Ising magnet Co3V2O8 in a transverse magnetic field

The application of a magnetic field transverse to the easy axis, Ising direction in the quasi-two-dimensional Kagome staircase magnet, Co3V2O8, induces three quantum phase transitions at low temperatures, ultimately producing a novel high field polarized state, with two distinct sublattices. New time-of-flight neutron scattering techniques, accompanied by large angular access, high magnetic field infrastructure allow the mapping of a sequence of ferromagnetic and incommensurate phases and their accompanying spin excitations. At least one of the transitions to incommensurate phases at \mu 0Hc1~6.25 T and \mu 0Hc2~7 T is discontinuous, while the final quantum critical point at \mu 0Hc3~13 T is continuous.Comment: 5 pages manuscript, 3 pages supplemental materia

Fifth Graders’ Creativity in Inventions with and without Creative Articulation Instruction

Industry and authors of 21st Century Skill Frameworks are calling for student proficiency in creativity, problem-solving, innovation, collaboration, and communication skills. This project involved 13 fifth grade gifted students in inventing products for a specified audience with a set of given materials, time limit, and topic constraints. The complex, challenging project supports Next Generation Science Engineering Process Standard 3-5-ETS1-2 and applies concepts of plant and animal adaptations. The study had a counterbalanced, repeated measures design in which student made an initial invention during the pretest, then participated in two trials with one in the control condition and the other in the experimental condition. The experimental condition involved creative articulation strategies of considering the audience for the invention, effective communication of the ways the product meets audience needs, and peer collaboration and feedback to improve the product ideas. Students found the invention process initially very challenging, especially generating unique ideas. No statistically significant differences were found in product creativity or student attitudes, which were very positive, between the two conditions of the experiment, likely because of the small sample size. Analysis of student advertisements revealed a statistically significant difference favoring the experimental condition with a medium effect size for including reasons the product meets audience needs in the advertisement. Examples of student-made products and teacher analysis of selected products provide ideas for coaching students into higher creative skill levels. Additionally, statistically significant gains in creativity skill occurred from the pretest to the invention of the product during the first trial and this was maintained into the second trial with large effect size. This study showed that multiple invention opportunities allowed students to develop their skills better than a single activity. The challenging, complex activities helped students achieve a state of flow as they worked during the experiment and helped students develop their creativity