ALBERT

Description: Aluminum-Lithium (Al-Li) alloys offer significant performance benefits for aerospace structural applications due to their higher specific properties compared with conventional Al alloys. For example, the application of Al-Li alloy 2195 to the space shuffle external cryogenic fuel tank resulted in weight savings of over 7,000 lb, enabling successful deployment of International Space Station components. The composition and heat treatment of 2195 were optimized specifically for strength-toughness considerations for an expendable cryogenic tank. Time-dependent properties related to reliability, such as thermal stability, fatigue, and corrosion, will be of significant interest when materials are evaluated for a reusable cryotank structure. Literature surveys have indicated that there is limited thermal exposure data on Al-Li alloys. The effort reported here was designed to establish the effects of thermal exposure on the mechanical properties and microstructure of Al-Li alloys C458, L277, and 2195 in plate gages. Tensile, fracture toughness, and corrosion resistance were evaluated for both parent metal and friction stir welds (FSW) after exposure to temperatures as high as 300 F for up to 1000 hrs. Microstructural changes were evaluated with thermal exposure in order to correlate with the observed data trends. The ambient temperature parent metal data showed an increase in strength and reduction in elongation after exposure at lower temperatures. Strength reached a peak with intermediate temperature exposure followed by a decrease at highest exposure temperature. Friction stir welds of all alloys showed a drop in elongation with increased length of exposure. Understanding the effect of thermal exposure on the properties and microstructure of Al-Li alloys must be considered in defining service limiting temperatures and exposure times for a reusable cryotank structure.

Description: In FSW (friction stir welding), the weld process performance for a given weld joint configuration and tool setup is summarized on a 2-D plot of RPM vs. IPM. A process envelope is drawn within the map to identify the range of acceptable welds. The sweet spot is selected as the nominal weld schedule. The nominal weld schedule is characterized in the expected manufacturing environment. The nominal weld schedule in conjunction with process control ensures a consistent and predictable weld performance.

Description: This paper presents viewgraphs on the effects of thermal exposure on the mechanical properties of both developmental and production mature Al-Li alloys. The topics include: 1) Aluminum-Lithium Alloys Composition and Features; 2) Key Characteristics of Al-Li Alloys; 3) Research Approach; 4) Available and Tested Material; and 5) Thermal Exposure Matrix. The alloy temperatures, gage thickness and product forms show that there is no deficit in mechanical properties at lower exposure temperatures in some cases, and a significant deficit in mechanical properties at higher exposure temperatures in all cases.

Description: This paper summarizes the results of processing GPS data from the AMSAT Phase 3D (AP3) satellite for real-time navigation and post-processed orbit determination experiments. AP3 was launched into a geostationary transfer orbit (GTO) on November 16, 2000 from Kourou, French Guiana, and then was maneuvered into its HEO over the next several months. It carries two Trimble TANS Vector GPS receivers for signal reception at apogee and at perigee. Its spin stabilization mode currently makes it favorable to track GPS satellites from the backside of the constellation while at perigee, and to track GPS satellites from below while at perigee. To date, the experiment has demonstrated that it is feasible to use GPS for navigation and orbit determination in HEO, which will be of great benefit to planned and proposed missions that will utilize such orbits for science observations. It has also shown that there are many important operational considerations to take into account. For example, GPS signals can be tracked above the constellation at altitudes as high as 58000 km, but sufficient amplification of those weak signals is needed. Moreover, GPS receivers can track up to 4 GPS satellites at perigee while moving as fast as 9.8 km/sec, but unless the receiver can maintain lock on the signals long enough, point solutions will be difficult to generate. The spin stabilization of AP3, for example, appears to cause signal levels to fluctuate as other antennas on the satellite block the signals. As a result, its TANS Vectors have been unable to lock on to the GPS signals long enough to down load the broadcast ephemeris and then generate position and velocity solutions. AP3 is currently in its eclipse season, and thus most of the spacecraft subsystems have been powered off. In Spring 2002, they will again be powered up and AP3 will be placed into a three-axis stabilization mode. This will significantly enhance the likelihood that point solutions can be generated, and perhaps more important, that the receiver clock can be synchronized to GPS time. This is extremely important for real-time and post-processed orbit determination, where removal of receiver clock bias from the data time tags is needed, for time-tagging of science observations. Current analysis suggests that the inability to generate point solutions has allowed the TANS Vector clock bias to drift freely, being perhaps as large as 5-7 seconds by October, 2001, thus causing up to 50 km of along-track orbit error. The data collected in May, 2002 while in three-axis stabilized mode should provide a significant improvement in the orbit determination results.