Alternative friction stir welding technology for titanium–6Al–4V propellant tanks within the space industry
Source abstract
Abstract
Friction stir welding (FSW) offers an appealing solid state joining alternative to traditional fusion welding techniques for titanium alloys because it reduces problems associated with high temperature processing. Propellant tanks are a critical component of every spacecraft and contain several weld seams and a prime candidate for this innovative technology. This paper reviews the current technological maturity of FSW relative to titanium alloys and considers the application with respect to a pressure vessel. FSW is currently in a period of significant investment by large engineering companies and international research institutions. The technology is advancing and evolving to cater for high temperature alloys. Stationary shoulder FSW and hybrid techniques show promising potential with respect to Ti–6Al–4V. The tool material and limited process window for this material are restrictive factors at present but can be overcome with future development.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: MXene and MAX Phase Materials · Advanced Welding Techniques Analysis · Titanium Alloys Microstructure and Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Welding Engineering and Laser Processing Centre, Cranfield University, Cranfield, UK
References (71)
Show source-provided references
1. 10.1002/978111997100910.1002/9781119971009 ↗
2. European Space Agency. 2014. Clean space – green technology [cited 2015 July]. Available from: http://www.esa.int/Our_Activities/Space_Engineering_Technology/Clean_Space/Green_technologies
3. ANSI AIAA S-080 · 1998
4. Debreceni MJ, Kuo TK, Jaekle DE. Development of a titaniumpropellant tank. 39th AIAA/ASME/SAE/ASEE joint propulsion conference, July 20–23; Huntsville, AL; 2003.10.2514/6.2003-4604 ↗
5. Tam WH · 2000
6. EADS Astrium GmbH. Spacecraft propellant tank manufacture [cited 2015 July]. Available from: http://cs.astrium.eads.net/sp/spacecraft-propulsion/propellant-tanks/manufacturing.html
7. European Space Agency. 2015. Launch Vehicles – Ariane 5 [cited 2015 June]. Available from: http://www.esa.int/Our_Activities/Launchers/Launch_vehicles/Ariane_5
8. Schultz H · 1993
9. Buhl N, Wagner G, Eifler D, 2013. Microstructural and mechanical investigations of friction stir welded Ti/Ti and Ti Alloy/Ti Alloy Joints. Friction stir welding processes VII, 141–149.10.1007/978-3-319-48108-1_15 ↗
10. Rummel WD · Mater Eval · 1982 · 40 · 922
11. NASA. 1996. Non-destructive evaluation requirements for fracture critical metallic components [cited 2015 July]. Available from: https://standards.nasa.gov/training/nasa-std-5009/index.html
12. Raj B · 2009
13. Ecord G M. NASA TN D-6975 · 1972
14. Ding J · 2006
15. Thomas WM · 1992
16. The Welding Institute. Friction stir welding patents – a stirring story [cited 2015 Aug]. Available from: http://www.twi-global.com/news-events/case-studies/friction-stir-welding-patents-a-stirring-story-002/
17. The Welding Institute. Knowledge summary – friction processing technology [cited 2015 July]. Available from: http://www.twi-global.com/technical-knowledge/knowledge-summaries/friction-processing-technologies/
18. 10.1533/978184569771610.1533/9781845697716 ↗
19. Thomas WM · 2005
20. 10.1007/BF0326666210.1007/BF03266662 ↗
21. 10.1080/09507116.2011.58135110.1080/09507116.2011.581351 ↗
22. 10.1179/136217110X1266577834842510.1179/136217110X12665778348425 ↗
23. 10.1080/09507116.2014.91142710.1080/09507116.2014.911427 ↗
24. European Space Agency · 2015
25. European Space Agency. Technology readiness levels. June 18th 2015 [cited 2015 Sep]. Available from: http://sci.esa.int/sre-ft/50124-technology-readiness-level/
26. Crocker AM, Doering KB, Meadows RG. Update on risk reduction activities for an F-1-based Advanced Booster for NASAs Space Launch System. 50th AIAA/ASME/SAE/ASEE Joint Propulsion conference; 2014 July 28–30; Cleveland, OH.10.2514/6.2014-3476 ↗
27. Threadgill PL, Leonard AJ, Shercliff HR, 2009 [cited 2015 Aug]. The Welding Institute. Friction stir welding of aluminium alloys. Available from: http://www.twi-global.com/technical-knowledge/published-papers/friction-stir-welding-of-aluminium-alloys/10.1179/174328009X411136 ↗
28. 10.1002/9781118062302.ch1010.1002/9781118062302.ch10 ↗
29. 10.1179/1879139512Y.000000001510.1179/1879139512Y.0000000015 ↗
30. 10.1016/j.jmatprotec.2014.11.04610.1016/j.jmatprotec.2014.11.046 ↗
31. Thompson B. Tungsten based tool material development for the friction stir welding of hard metals. In: Mishra R, Mahoney MW, Sato Y, Hovanski Y, Verma R, editors. Friction stir welding and processing VI. Seattle: Wiley and sons inc.; 2011. p. 105–112.10.1002/9781118062302.ch14 ↗
32. 10.1179/136217109X42583810.1179/136217109X425838 ↗
33. 10.1179/136217109X1246454988333010.1179/136217109X12464549883330 ↗
34. Buffa G, Fratini L, Micari F. On the choice of tool material in friction stir welding of titanium alloys. Vol. 40, North American manufacturing research conference, Notre Dame, IN, USA; 2012.
35. Thompson B. Tool degradation characterization in the friction stir welding of hard metals [MSc thesis]. Ohio State University; 2010.
36. Thompson B. Friction stir welding of hardmetals using advanced refractory alloys – Report No. MR1013. EWI Cooperative Research Program Report; 2010.
37. 10.1179/1362171811Y.000000002310.1179/1362171811Y.0000000023 ↗
38. 10.1016/j.msea.2007.10.06210.1016/j.msea.2007.10.062 ↗
39. Kumar N, Rodelas J, Mishra RS. The effects of friction stir processing on the microstructural evolution and mechanical properties of Ti-6Al-4V Alloy. Friction stir welding and processing. TMS Annual Meeting, San Francisco, CA; 2009. p. 45–53.
40. Mishra RS · 2007
41. Boyer R · 1994
42. Lütjering G · 2007
43. Porter DA · 1981
44. Metals Handbook, Vol.2 · 1990
45. Thomas WM · Weld World · 2002 · 47 · 10
46. Deformation induced abnormal grain growth in friction stir weld during solution heat treatment (cited 2016 March). Available from: https://www.linkedin.com/pulse/deformation-induced-abnormal-grain-growth-friction-stir-anupam-kundu. Written by Anupam Kundu.
47. 10.1016/j.msea.2007.08.05110.1016/j.msea.2007.08.051 ↗
48. 10.1016/j.matdes.2012.10.05110.1016/j.matdes.2012.10.051 ↗
49. 10.1016/j.matdes.2012.12.02410.1016/j.matdes.2012.12.024 ↗
50. 10.1016/j.matdes.2009.12.01410.1016/j.matdes.2009.12.014 ↗
51. 10.1016/j.matdes.2009.08.02510.1016/j.matdes.2009.08.025 ↗
52. 10.1007/s11837-015-1376-x10.1007/s11837-015-1376-x ↗
53. 10.1111/ffe.1229110.1111/ffe.12291 ↗
54. 10.1007/s11665-015-1610-210.1007/s11665-015-1610-2 ↗
55. 10.1111/j.1460-2695.2008.01258.x10.1111/j.1460-2695.2008.01258.x ↗
56. 10.1179/136217112X1343916018419610.1179/136217112X13439160184196 ↗
57. 10.31399/asm.tb.ttg2.978162708269310.31399/asm.tb.ttg2.9781627082693 ↗
58. 10.1007/s11661-010-0304-510.1007/s11661-010-0304-5 ↗
59. Bussu G, Stramaccioni D, Kalsch I. Experimental assessment of the susceptibility to stress corrosion cracking of Ti-6Al-4V alloy exposed to MON-1 propellant tank environment. ESA International Propulsion Conference, June 2–4; Sardini, 2004.
60. Russell MJ, Threadgill PL, Thomas MJ, Static shoulder friction stir welding of Ti-6Al-4V. 11th World Conference on Titanium, 2007 July 3–7; Kyuoto, Japan: Japan Institute of Metals; 2007. p. 1095–1098.
61. The Welding Institute. Friction stir welding process variants and recent industrial developments, 2007 [cited 2015 Sep]. Available from: http://www.twi-global.com/EasysiteWeb/getresource.axd?AssetID=2846145
62. 10.1007/s11661-011-0606-210.1007/s11661-011-0606-2 ↗
63. Stotler T · Adv Mater Process · 2009 · 167 · 35
64. Kou S, Cao G. 2006. Wisconsin Alumni Research Foundation. Arc-enhanced friction stir welding. Patent No. US,7078,647 B2, 2006 [cited September 2015]. Available from: http://www.warf.org/documents/ipstatus/P05041US.PDF.
65. 10.1016/j.matdes.2011.12.01810.1016/j.matdes.2011.12.018 ↗
66. 10.1016/j.matdes.2013.04.05710.1016/j.matdes.2013.04.057 ↗
67. Park K. Development and analysis of ultrasonic assisted friction stir welding process [PhD thesis]. University of Michigan; 2009.
68. 10.1007/s00170-014-5806-710.1007/s00170-014-5806-7 ↗
69. Lapilli G, Wise B, Gutierrez H, Characterisation of elastomeric diaphragm motion with a spacecraft tank during ground operation. 51st AIAA/ASME/SAE/ASEE Joint Propulsion conference, 2015; Orlando, Florida.10.2514/6.2015-4075 ↗
70. 10.1016/j.matdes.2014.12.01510.1016/j.matdes.2014.12.015 ↗
71. Edison Welding Institute. 2014 [cited 2015 Oct]. Modelling the electron beam welding of intermediate pressure compressor drums. Rolls-Royce. Available from: http://ewi.org/eto/wp-content/uploads/2014/10/12-Beech-2014-Seattle-EB-Welding.pdf