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.
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.
The spherical tank dome was manufactured from a flat plate "blank" made of the 2195 alloy. The blank was constructed by friction stir welding together two commercial off-the-shelf plates in order to produce a large starting blank, reducing the cost of raw materials. The welded plate blank was then spun formed to create the single-piece tank dome.
This is the first time this combination of twin manufacturing processes has been successfully applied to produce a full-scale 2195 aluminum-lithium dome.
Two additional, full-scale development tank domes are scheduled for manufacture and testing in coming months as part of the joint, two-year technology demonstration program.
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