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General Disclaimer One Or More of the Following Statements May Affect This Document General Disclaimer One or more of the Following Statements may affect this Document This document has been reproduced from the best copy furnished by the organizational source. It is being released in the interest of making available as much information as possible. This document may contain data, which exceeds the sheet parameters. It was furnished in this condition by the organizational source and is the best copy available. This document may contain tone-on-tone or color graphs, charts and/or pictures, which have been reproduced in black and white. This document is paginated as submitted by the original source. Portions of this document are not fully legible due to the historical nature of some of the material. However, it is the best reproduction available from the original submission. Produced by the NASA Center for Aerospace Information (CASI) MASSACHUSETTS INSTITUTE OF TEC'.-INOLOGY DEPARTMENT OF OCEAN ENGINEERING SEP 83 CAMBRIDGE. MASS. 02139 RECEIVED FAVUV wrw STI DEPI- , FINAL REPORT "Wo Under Contract No. NASW-3740 (M.I.T. OSP #93589) ON FEASIBILITY OF REMOTELY MANIPULATED WELDING IN SPACE -A STEP IN THE DEVELOPMENT OF NOVEL JOINING TECHNOLOGIES- Submitted to Office of Space Science and Applications Innovative Utilization of the Space Station Program Code E NASA Headquarters Washington, D.C. 20546 September 1983 by Koichi Masubuchi John E. Agapakis Andrew DeBiccari Christopher von Alt (NASA-CR-1754371 ZEASIbILITY CF RZ,1JTL": Y `84-20857 MANIPJLATED WELLINu iN SPAI.E. A STEP IN THE Uc.Y1;LuPdENT OF NUVLL Ju1NING Tkk ;HNuLUGIES Final Peport (c;dssachu6etts Irist. or Tccli.) U11CIds ibJ p HC Al2/Mk AJ 1 CSCL 1jI G:i/.i7 OOb47 i i rACKNOWLEDGEMENT The authors wish to acknowledge the assistance provided by M.I.T. staff members including Professor David L. Akin of the Departmen t of Aeronautics and Astronautics, and Professor Thomas B. Sheridan and Dr. Dana Yoerger of the Department of Mechanical Engineering. The authors also wish to thank Ms. Muriel Morey, Mrs. Eileen MacIntosh, and Ms. Linda Sayegh for providing necessary assistance including editing, drawing, and typing. :^-,•,.x.. rx^.'?,v ;err--,-^_. ,. ..o.+nom.-,. ...-^^q':: tnrr."iq'."Fi^n^y'a: "'`^y ^'^^yti'^3 ii SUMMARY This is the final report of a six-month research program entitled, "Feasibility of Remotely Manipulated Welding in Space - A Step in the Development of Novel Joining Technologies". The program was performed at the Massachusetts Institute of Technology for the Office of Space Science and Applications, NASA, as a part of the Innovative Utilization of the Space Station Program. The objective of this research has been to initiate a research i program for the development of packaged, remotely controlled welding systems for space construction and repair. The research effort included the following tasks: Task 1: Identification of probable joining tasks in space Task 2: Identification of required levels of automation in space welding tasks Task 3: Development of novel space welding concepts Task 4: Development of recommended future studies Task 5: Preparation of the final report. As the first step for identifying probable joining tasks in space, a survey was made of existing publications on space welding and related subjects. Section 2.1 presents a summary of this survey. A more detailed account of the literature survey is presented in APPENDIX A, which includes 121 annotated references. Probable joining tasks in space may be,classified, depending upon the complexities and scales of the tasks, into the following three categories: Category 1: Construction and repair of simple, small tools, equipment, components, and structural members • Category 2: Maintenance and repair of major members of space stations Category 3: New construction of large, complex space structures. f .v,.w+•, ern'2 k`. 3,151 iiiii Section 2.4 discusses probable joining tasks in space under these categories. Regarding candidate materials to be investigated, aluminum alloys, especially those in 2000 series have been selected as primary materials. Since most space structures will be fabricated with light r, structures, research should be directed toward fabrication of metal structures in thin sheets. Gas tungsten arc welding (GTAW) and capacitor discharge stud welding have been selected as primary welding processes. Under Task 2, the following subjects have been studied: (1) Welding task analyses, including general task analysis, tool manipulation, selection of the process type and parameters, process control, and inspection and quality control. (2) Operational modes for space welding fabrication, including manual welding by an operator in the remote site, remotely manipulated welding, and totally autonomous, unmanned welding systems. (3) Experimental study. A limited experimental study was made to examine the positioning and path tracking manual control tasks. Under Task 3, discussions are presented on the following subjects: (1) Development of space welding technologies which do not require on-site presence of welding engineers and welders. Discussions cover (a) development of completely remote welding technolog y , (b) development of integrated and automated welding systems which can be operated by persons with no welding skill, and (c) development of technologies of welding through telepresence. (2) Development of new welding processes and procedures uniquely suited for space applications. Discussions cover (a) space electron beam welding technology, (b) space exothermic x brazing technology, and (c) solar welding systems. ,} J H iv Under Task 4, the following six research programs have been recommended: Program U1: Development of space stud welding systems which can be remotely manipulated. Program 02: Development of "instamatic® " GTAW systems for space appli- cations which can be operated by an astronaut with no welding training. Program #3: Development of flexible space welding systems. Program (14: Research on space welding using GMAW, EBW, and LBW processes. Program 115: Research on special joining techniques suited for space applications. Program 116: Development of integrated fabrication systems for certain complex structures. i KEYWORDS: Welding in space, Remotely manipulated welding in space, Space stud welding, Space "instamatic ® " welding systems. r e;,l L4 N v TABLE OF CONTENTS PAGE ACKNOWLEDGEMENT . i I SUMMARY . 1. INTRODUCTION . 1 1.1 Statement of the Problem . 1 1.2 Objective and Tasks . 4 1.3 Possible Non-Space Applications of Novel Space Welding Concepts . 5 2. TASK 1: IDENTIFICATION OF PROBABLE JOINING TASKS IN SPACE 8 2.1 Survey of Past Studies on Space Welding and Related Subjects . 8 2.2 Basic Considerations for Identifying Probable Joining Tasks in Space . 19 2.3 Applicabilities of Existing Welding Processes to Space . 35 2.4 Probable Joining Tasks in Space . 40 2.5 Selection of Candidate Base Materials and Potential Welding Problems . 57 3. TASK 2: IDENTIFICATION OF REQUIRED LEVEL OF AUTOMATION IN SPACE WELDING TASKS . 63 3.1 Welding Task Analysis . 63 3.2 Operational Modes for Space Welding Fabrication . 73 3.3 Experimental Study . 81 4. TASK 3: DEVELOPMENT OF NOVEL SPACE WELDING CONCEPTS . 84 4.1 Development of Space Welding Technologies which do not Require On-Site Presence of Welding Engineers and Welders. 84 4.2 Development of New Welding Processes and Procedures Uniquely Suited for Space Applications . 88 5. TASK 4: RECOMMENDED FUTURE STUDIES . 89 5.1 Research Program 111: Development of Space Stud Welding Systems which can be Remotely Manipulated . 92 i 5.2 Research Program 112: Development of "Instamatic® GTAW Systems for Space Applications which can be Operated by an Astronaut with no Welding Training . 100 5.3 Research Program 113: Development of Flexible i. Space Welding Systems . 107 kb L3 vi TABLE OF CONTENTS (continued) PAGE 5.4 Research Program 114: Research on Space Welding Using GMAW, EBW. AND LBW Processes . 114 5.5 Research Program U5: Research on Special Joining Techniques Suited for Space Applications . 117 5.6 Research Program U6: Development of Integrated Fabrication Systems for Certain Complex Space Structures . 117 6. REFERENCES . 119 APPENDIX A REVIEW AND ANALYSIS OF THE SPACE ENVIRONMENT AND PREVIOUS SPACE WELDING EXPERIMENTS APPENDIX B PRESENT STATUS OF THE DEVELOPMENT OF "INSTAMATIC WELDING SYSTEMS APPENDIX C A PRELIMINARY INVESTIGATION OF THE FEASIBILIGY OF USING STUD WELDING IN SPACE APPENDIX D EXPERIMENTAL STUDY ON THE PERFORMANCE OF REMOTELY MANIPULATED SPACE WELDING } y S 1 1. INTRODUCTION A six-month research program entitled, "Feasibility of Remotely Manipulated Welding in Space - A Step in the Development of Novel Joining Technologies" was performed at the Massachusetts Institute of Technology for the Office of Sp-ace Science and Applications, NASA, as a part of the Innovative Utilization of the Space Station Program. This is the final report of this research. 1.1 Statement of the Problem In order to establish permanent human presence in space we must develop technologies of constructing and repairing space stations and other space structures. In early stages of the Space Station Program, most construction jobs will be performed on earth and the fabricated modules will then be delivered to space by the Space Shuttle. Only limited final assembly jobs, which may be primarily mechanical fastening, will be performed on site in space. Such fabrication plans, however, limit the designs of these structures, because each module-must fit inside the transport vehicle and it must withstand launching stresses which could be
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