NASA Scientific and Technical Aerospace Reports - The University ...

of thermographic, shearographic, and phased array ultrasonic methods to the bonding demonstration article as well as various
smaller test panels featuring design specific defect types and geometric features.
Author
Ares 1 Upper Stage; Bulkheads; Nondestructive Tests; Service Life; Composite Materials
20100017377 NASA Marshall Space Flight Center, Huntsville, AL, USA
Development of Weld Inspection of the Ares I Crew Launch Vehicle Upper Stage
Russell, Sam; Ezell, David; March 22, 2010; 29 pp.; In English; American Society for Nondestructive Testing Spring
Research Symposium and Conference, 22-26 Mar. 2010, Williamsburg, VA, USA
Report No.(s): M10-0159; M10-0424; Copyright; Avail.: CASI: A03, Hardcopy
ONLINE: http://hdl.handle.net/2060/20100017377
NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement
in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon
the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to
assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are
to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir
welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the
fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of
self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs
from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut
on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld,
so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to
overcome. The metal microstructure and possible defects are different from other weld processes. Friction plug welds will be
used to close out the hole remaining in the radial welds when friction stir welded. This plug welding also has unique challenges
in inspection. The current state of development of these inspections will be presented, along with other information pertinent
to NDE of the Ares I.
Author
Friction Stir Welding; Nondestructive Tests; Welded Joints; Ares 1 Upper Stage; Ares 1 Launch Vehicle
20100017543 NASA Johnson Space Center, Houston, TX, USA
Crew Exploration Vehicle Environmental Control and Life Support Ddevelopment Status
Lewis, John F.; Barido, Richard A.; Carrasquillo, Robyn; Cross, Cynthia d.; Rains, Ed; Tuan, George C.; [2010]; 4 pp.; In
English; ICES Meeting, 11-15 Jul. 2010, Barcelona, Spain; Original contains color illustrations
Contract(s)/Grant(s): 644423.02.36.12.10
Report No.(s): 2010-01-2457; JSC-CN-20395; Copyright; Avail.: Other Sources
The Orion Crew Exploration Vehicle (CEV) is the first crew transport vehicle to be developed by the National Aeronautics
and Space Administration (NASA) in the last thirty years. The CEV is being developed to transport the crew safely from the
Earth to the Moon and back again. This year, the vehicle continued to go through design refinements to reduce weight, meet
requirements, and operate reliably. Preliminary Design Review was performed and long lead procurement items were started.
The design of the Orion Environmental Control and Life Support (ECLS) system, which includes the life support and active
thermal control systems, is progressing through the design stage into manufacturing. This paper covers the Orion ECLS
development from April 2009 to April 2010
Author
Crew Exploration Vehicle; Temperature Control; Life Support Systems; Design Analysis; Active Control; Transport Vehicles;
Environmental Control
20100017559 NASA, Washington, DC USA
Versatile honeycomb matrix heat shield
Zell, Peter T., Inventor; February 16, 2010; 6 pp.; In English
Patent Info.: Filed July 17, 2008; US-Patent-7,662,459; US-Patent-Appl-SN-12/175,379; No Copyright; Avail.: CASI:
A02, Hardcopy
ONLINE: http://hdl.handle.net/2060/20100017559
A thermal protection system for atmospheric entry of a vehicle, the system including a honeycomb structure with selected
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