russ section P6, ortside segments ation. Photos courtesy of NASA a stable environment for scientific, tech- a stable environment viding enture in history. Its crews are conducting enture in history. The Port Side P6 truss segment hangs suspended from a crane, moving through the Space Station Processing Facility, on its way to launch on the Space Shuttle Endeavour. The P6 comprises Solar Array Wing-3 and the Integrated Electronic Assembly, installed on the ISS in November 2000. nological and commercial research. Building the ISS and more than 100,000 space agency involves contractor personnel from 16 countries, including more than 10,000 first tosuppliers—truly fourth-tier an example of international cooper The ISS is the most complex international scientific The ISS v and are research to support space exploration, pro A Safe Hand-Hold in Space A Safe Hand-Hold : Y Innovation launches into orbit, thanks to aluminum industry manufacturers who launches into orbit, thanks to aluminum industry Innovation tubing for the truss structures that link together are supplying extruded aluminum engineers are working Boeing Company (ISS). the International Space Station scale during construction and assembly of the newest with extruders on a massive segments S3, S4, S6, and P extruded truss sections: Starboard launching in Spring, 2005. T P3, P4 and P5, scheduled to begin of A marvel configuration. the current ISS 2000, supports launched in November is truly flourishing program ISS this vast science and aerospace engineering, thanks to aluminum extruders across the globe. MORE CENTUR TIONAL SPACE STATION SKYROCKETS TIONAL STATION SPACE COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 EXTRUDERS O 21ST International Space Station Skyrockets into 21st Century Space Station Skyrockets into International EXTRUDED ALUMINUM TRUSS STRUCTURES LINK STATION MODULES TOGETHER IN THE STRUCTURES LINK STATION MODULES TOGETHER IN EXTRUDED ALUMINUM TRUSS VENTURE IN HISTORY MOST COMPLEX SCIENTIFIC INTERNA INT With Earth on the horizon, the International Space Station, as seen from aboard the Space Shuttle Discovery. ALUMINUM

ALUMINUM EXTRUSION SHOWCASE AEROSPACE—page 1 ation will s port side, Photos courtesy of NASA ated truss configur S integr ISS Technical Configuration Chart, July 2004. viding power from the superstructure’ A Safe Hand-Hold in Space A Safe Hand-Hold with two sections pro Extruded aluminum outboard truss sections house the U.S. power generation and power generation sections house the U.S. Extruded aluminum outboard truss outboard truss sections house power generation distribution system. Four modules, electrical feeding the station’s with its solar arrays measure 361 feet end-to-end, one acre of solar collection, comprises approximately system. This power generation slated for completion in construction is ISS than 80 kw of power. more providing 2010. and two from the starboard side. The final IS and two from the starboard side. COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 EXTRUDERS International Space Station Skyrockets into 21st Century Space Station Skyrockets into International Since the first module’s launch in November 1998, 12 major ISS components have been assembled in space. Components are been assembled have components ISS 1998, 12 major launch in November Since the first module’s cargo elements in the Space or combine as separately, sections, designed to launch inboard and outboard truss connected by a robotic crane. the astronauts, using by assembled hands-on in space to low Earth orbit, then delivered Shuttle. They are truss P1 (port side segment one) S1 (starboard segment one), and truss segment, or central segment zero) The S0 (starboard Quest airlock, and Destiny the U.S. Progress cargo vehicle, uniting the Russian and assembled in 2002, sections were launched Lab modules. ASTRONAUTS WORK HAND-IN-HAND WITH ALUMINUM EXTRUDERS WORK HAND-IN-HAND WITH ASTRONAUTS MORE Astronauts routinely work outside during space walks, using the Crew Equipment and Translation Aid (CETA) cart, as they build and maintain the ISS. ALUMINUM

ALUMINUM EXTRUSION SHOWCASE AEROSPACE—page 2 Photos courtesy of NASA An astronaut performs external tasks on the ISS’s U.S.-built Unity Node. y-three space flights will be y-three ort A Safe Hand-Hold in Space A Safe Hand-Hold - ” ark and Huntington Beach, California. F ark and Huntington Beach, California. s Manager of the es the extruded alu conducted construction. the course of the station’s over Thanks in part to Boeing’s Truss Design Team, the international crews are successfully the international Design Team, Truss Boeing’s Thanks in part to Space Station, currently powering up the amazing International and building, operating 240 feet wide, and 90 measuring 146 feet long, 400,000 pounds, weighing in at over including much of the truss structures, extruded tubing is used in feet high. Aluminum teams in Boeing engineering sections designed by outboard and inboard truss a dozen Canoga P y and surface finish. russ & Manufacturing at Boeing, y that mak The ISS, in October 2000, following deployment of the Z1 truss structure. cellent qualit COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 ease of machinabilit am, and John Badalich, Boeing’ russ Elements at Boeing Canoga Park, agree that russ Elements at Boeing Canoga Park, , Director of Outboard T EXTRUDERS er International Space Station Skyrockets into 21st Century Space Station Skyrockets into International MORE Karl Wefers, Boeing’s Manager of Materials & Process on the ISS Manager Boeing’s Wefers, Karl Space Progr Outboard T aluminum mechanical properties the excellent extrusions provide sites the needed for this mission-critical application. Josker outstanding Bob Josk get a consistent extruded part minum so easy to work with. “We notes, “Direct extrusion through Josker finish,” with a good anodized the die shape allows ex TRUSS DESIGN TEAM PUSHES THE ENVELOPE TEAM PUSHES THE ENVELOPE TRUSS DESIGN ALUMINUM Truss segment Starboard Zero (SO) takes center stage. Workers check the structure, as the Canadian Mobile Transporter, power distribution system modules, heat pipe radiator for cooling, and a pair of rate gyroscopes are installed. The structure will ultimately extend the length of a football field.

ALUMINUM EXTRUSION SHOWCASE AEROSPACE—page 3 Photos courtesy of NASA efers affirms, “The electrical A Safe Hand-Hold in Space A Safe Hand-Hold COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 EXTRUDERS International Space Station Skyrockets into 21st Century Space Station Skyrockets into International MORE Engineers and crew are pleased with the trusses’ stable performance in orbit. The truss teams’ W Engineers and crew are pleased with the trusses’ stable performance Against the backdrop of Earth and space, the ISS separates from Space Shuttle Endeavour during undocking over western Kazakhstan in June 2002. Against the backdrop of Earth and space, the ISS separates from Space Shuttle power system the trusses house has provided 100 percent power availability since solar array deployment in December 2000.” deployment since solar array percent power availability 100 power system the trusses house has provided the extruded aluminum’s be considered for future structures in space, because will always extrusions “Aluminum He sums up, applications.” mechanical and optical properties are so ideally suited to space ALUMINUM

ALUMINUM EXTRUSION SHOWCASE AEROSPACE—page 4 vided the Photos courtesy of NASA Surrounded by Kennedy Space Center workers in the Space Station Processing facility at KSC, Florida, in February 2004, Boeing senior truss manager Chuck Hardison (left), presents the “key” for Starboard truss segments S3 and S4 to Scott Gahring (center), ISS vehicle office manager, Johnson Space Center. A Safe Hand-Hold in Space A Safe Hand-Hold This view of the Space Station Processing Facility shows elements lined up in various stages of preparation for future flights to the ISS. cle, influencing the current design. Thorough testing and review pro cle, influencing the current design. truss design team with lots of practical feedback on assembly, maintenance and safety feedback on assembly, practical truss design team with lots of issues. Boeing engineers in Canoga Park and Huntington Beach work closely with Boeing Beach work closely with and Huntington in Canoga Park Boeing engineers the prime interface with is systems integrator Texas—the personnel in Houston, assembled under constructed and was NASA. mock-up Buoyancy” “Neutral An ISS feedback early in the truss to simulate on-orbit conditions. Astronauts provided water design cy COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 EXTRUDERS tems testing. russ design and test teams support the Kennedy Space russ design and test teams support the Kennedy International Space Station Skyrockets into 21st Century Space Station Skyrockets into International T activities, test Center in Florida with launch integration pre-launch coordination, and multi-element integrated sys MORE ENGINEERS DIVE DEEP TO ENSURE SAFETY DEEP TO ENSURE SAFETY ENGINEERS DIVE An astronaut wears a training version of the extravehicular mobility unit (EMU) space suit during an underwater simulation of a space walk, conducted in the Neutral Buoyancy Laboratory in Houston, Texas. ALUMINUM

ALUMINUM EXTRUSION SHOWCASE AEROSPACE—page 5 s Badalich ed aluminum Photos courtesy of NASA s effects are challenging. Boeing’ ’ vide stability to the attachment interface, along to the attachment vide stability vironment A Safe Hand-Hold in Space A Safe Hand-Hold vides superior optical properties, because anodiz The ISS in sunlight and shadows, viewed by the Space Shuttle The ISS in sunlight and shadows, viewed Discovery’s crew optical alignment system (COAS) during separation operations, in August 2001. ed surface finish on the extrusions pro COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 EXTRUDERS International Space Station Skyrockets into 21st Century Space Station Skyrockets into International MORE ALUMINUM During truss component assembly in space, the on-orbit thermal en During truss component assembly in space, the on-orbit thermal explains, “In space, direct sunlight and shadowing cause wide swings in temperature when joining truss elements, so the truss- swings in temperature explains, “In space, direct sunlight and shadowing cause wide tubes pro to-truss attachment interface is critical. The trusses’ large extruded adds, “The Josker into the attachment design.” compliance being incorporated with additional thermal expansion/contraction with stain- truss members feature large elements of extruded aluminum tubing that are fastened together primary structural great- retains the yet the lightest possible weight, joints, extruded aluminum tubing provides less steel bolts. In these structural est strength. The anodiz doesn’t get as hot, giving better overall thermal control.” thermal control.” doesn’t get as hot, giving better overall

ALUMINUM EXTRUSION SHOWCASE AEROSPACE—page 6 MORE Photos courtesy of NASA A Safe Hand-Hold in Space A Safe Hand-Hold Get a grip! Mission specialists work together on the last of three space walks on mission STS-88. They both have a firm grasp on the gold-anodized extruded handrails. crewmember on an EVA. Critical to all EVAs are the hundreds are the Critical to all EVAs crewmember on an EVA. the exterior covering of extruded aluminum handrails of the which allow the astronauts to International Space Station, truss structures during construction assem- negotiate the vast lines that attach to crew are also used to tether blies. Handrails that occur round the clock, and equipment for tests and repairs is distanced apart from the next Each handrail a year. 365 days reach. the length of an astronaut’s one by COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 EXTRUDERS International Space Station Skyrockets into 21st Century Space Station Skyrockets into International ALUMINUM EXTRUDED ALUMINUM TRUSS STRUCTURES LINK STATION MODULES TOGETHER IN THE LINK STATION MODULES TRUSS STRUCTURES EXTRUDED ALUMINUM HISTORY SCIENTIFIC VENTURE IN MOST COMPLEX outer them from floating off into astronaut—keeping ISS for every are both anchors and lifelines handrails Extruded aluminum are anodized activities). Handrails (extra-vehicular as they are called or EVA outside on a space walk, venture space when they every for essential point of safety truss structures—an out visually against the clear silver in a bright gold finish to stand A IN SPACE HAND-HOLD SAFE Hanging tough: During space walks, astronauts rely on every extruded aluminum handrail to do its job without fail. Handrails are always within reach, Hanging tough: During space walks, astronauts rely on every extruded aluminum serving as tether anchors for equipment, and lifelines for the ISS crew.

ALUMINUM EXTRUSION SHOWCASE AEROSPACE—page 7 Photos courtesy of NASA © Copyright 2004, Aluminum Extruders Council. v/ http://spaceflight.nasa.go Between April and October 2004, Expedition 9’s commander and ISS astronauts monitor the astronauts monitor and ISS commander October 2004, Expedition 9’s Between April and computer software, the station’s upgrade Progress re-supply ships, of two Russian arrival scientific experiments. During arm (Canadarm2), and conduct robotic work with the station’s needed for the and communications equipment will install retro reflectors astronauts EVAs, cargo ship taking flight next year. the Vehicle, Transfer Automated docking of the European in the components to be key are, and will continue truss structures and handrails Boeing’s thanks in part to crews’ safety, critical to the ISS success, and Station’s International Space aluminum extrusions. strong, lightweight, and cost-effective the long-term attributes of reliable, opportunities from and sighting activities aboard the ISS, additional information on crew For Earth, log on at: The European astronaut returned to Earth with the Expedition 8 crew on April 30, 2004, while the Expedition 9 crew The European astronaut returned to Earth with the Expedition 8 crew on April continue to work and live aboard the ISS, returning in October, 2004. COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 • www.aec.org COUNCIL • 1000 N. Rand Road, Suite 214 • Wauconda, IL 60084 USA • Tel. 847/526-2010 EXTRUDERS BACK TO TOP Aluminum extruders providing truss and handrail extrusions for the ISS include: Alcoa, Inc., Kaiser Aluminum, Kaiser include: Alcoa, Inc., extrusions for the ISS truss and handrail Aluminum extruders providing issues! for more extruded aluminum application stories in future Watch and LeFiell Manufacturing. Hoogovens/Reynolds, to share, email the Showcase staff at: [email protected] an application story have If you The Russian Mission Commander (top), U.S. science officer and flight engineer (center), and European Space Agency astronaut (bottom) of the Expedition 9 Crew prepare to board the Soyuz TMA-4 vehicle for their launch to the ISS on April 19, 2004. ALUMINUM

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