New electron beam gun for welding in space

Paton, B. E.; Lobanov, L.M.; Naidich, Yu. V.; Asnis, Yu.A.; Zubchenko, Yu.V.; Ternovyi, E. G.; Волков, В. С.; Kostyuk, B. D.; Umanskii, V. P.

doi:10.1080/13621718.2018.1534794

Cited by 15 publications

(4 citation statements)

References 14 publications

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“…Obviously, the existing methods of deployment and assembly on orbit are very limited [6,7], and new ways of building are urgently needed. The use of various space manufacturing technologies, including on-orbit additive manufacturing [8,9] and on-orbit welding [10,11], to produce the rods is one of the effective ways to solve the bottleneck problem of large space trusses on orbit. In this paper, an on-orbit cold forming manufacturing technology is proposed for the production of space truss rods, which mainly uses small cold roll forming machines to coil the raw material into rods to realize on-orbit manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Research on Cold Roll Forming Process of Strips for Truss Rods for Space Construction

Yang,

Han,

2023

Materials

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In this paper, a new technology for on-orbit cold forming of space truss rods is proposed. For the cold roll forming process of asymmetric cross sections of thin strips, the effects of roll gap and roll spacing on the forming of asymmetric cross sections of strips were investigated using ABAQUS simulation + experiments. The study shows the following. When forming a strip with a specific asymmetric cross section, the stresses are mainly concentrated in corners 2/4/6, with the largest strain value in corner 2. With increasing forming passes, when the roll gap is 0.3 mm, the maximum equivalent strain values are 0.09, 0.24, 0.64 sequentially. Roll gaps of 0.4 mm and 0.5 mm equivalent strain change amplitude are relatively similar, and their maximum equivalent strain values are approximately 0.07,0.15, 0.44. From the analysis of the stress–strain history of the characteristic nodes in corners 2/4/6, it can be seen that the stress and strain changes in the deformation process mainly occur at the moment of interaction between the upper and lower rollers, where the stress type of node 55786 shows two tensile types and one compressive type, the stress type of nodes 48594 and 15928 shows two compressive and one tensile type, and the strain of the three nodes is in accordance with the characteristics of plane strain. When the roll gap is about 0.4 mm, the forming of the strip is relatively good. With increased roll spacing, the strip in the longitudinal stress peak through the rollers shows a small incremental trend, but the peak stresses are 380 Mpa or so. When the roll spacing is 120 mm, the longitudinal strain fluctuation of the strip is the most serious, followed by the roll spacing at 100 mm, and the minimum at 140 mm. Combined with the fluctuation in strip edges under different roll spacings, manufacturing cost and volume and other factors, a roll spacing of 100 mm is more reasonable. It is experimentally verified that when the roll gap is 0.4 mm and the roll spacing is 100 mm, the strip is successfully prepared in accordance with the cross-section requirements. When the rolling gap is 0.3 mm, due to stress–strain concentration, the strip is prone to edge waves in forming. The top of corner 2 of the flange triangular region is susceptible to intermittent tear defects, and the crack extension mechanism is mainly based on the cleavage fracture + ductile fracture.

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Section: Introductionmentioning

confidence: 99%

Research on Cold Roll Forming Process of Strips for Truss Rods for Space Construction

Yang,

Han,

2023

Materials

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“…Under this background, the on-orbit manufacturing technology has become an important technical approach to crack the development of large-scale space structures in the future. With the development of on-orbit manufacturing technology research [4][5][6], on-orbit manufacturing of space trusses has become the future development direction, such as on-orbit additive manufacturing technology [7,8], on-orbit welding [9,10], etc. In this paper, the method of on-orbit plastic forming is proposed to produce space truss rods [11].…”

Section: Introductionmentioning

confidence: 99%

Simulation and analysis of mechanical properties of cold-formed lock-seam of truss rods for on-orbit construction

Yang

Han²,

Liu³

et al. 2022

Eng. Res. Express

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In this paper, a new process of spiral cold forming of truss rods for on-orbit construction is proposed. The influence of the width of the lock-seam overlapping region, stirp thickness and lock-seam buckle structure types on the mechanical properties of the rods’ lock-seam was investigated by using a method combining of single tensile experiment and numerical simulation. The results show that for the flat buckle samples with the stirp thickness of 0.3mm, with the increase of the width of overlapping region of the lock-seam, the maximum occlusal force and maximum occlusal strength of the lock-seam are monotonically decreasing. Although the simulated maximum occlusal force is slightly higher than the actual maximum occlusal force, the simulation results show reasonable agreement with the experimental values. In the simulation, with the increase of the stirp thickness, the maximum occlusal force of the flat buckle has a linear increase, while the maximum occlusal strength increases slightly. Compared with the flat buckle type, when the lock-seam is designed as a pressed rib buckle type, the overall mechanical properties of the lock-seam are improved by 80%. It is more effective to improve the mechanical properties of the rods’ lock-seam by changing the buckle type.

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“…The applicability of EBW is not limited to producing of vacuum-tight joints of a wide range of metals and non-metallic materials [2], [3], [4] and can be expanded to the field of additive technologies [5] and the processes of protective coating for using in space vacuum conditions [6]. In addition, EBW equipment for work in space was successfully tested in real conditions [7], [8], [9] proved its effectiveness and safety [10] and now it is the object of further optimization at the stage of on-land tests [11].…”

Section: Introductionmentioning

confidence: 99%

Some Issues of Repairing Manned Space Vehicles in Outer Space Using Electron Beam Welding

Lobanov¹,

Asnis²,

Ternovy³

et al. 2021

SSP

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A new generation of electron beam tool for welding during assembly and repair-restoration works on board of manned space vehicles in open space was demonstrated. The tool includes a small-sized electron beam gun (EBG) with an electron beam power of up to 2.5 kW and a high-voltage power source with a voltage of 10 kV. The design of the electron-optical system of EBG allows using it in both manual as well as in automatic mode applying robotic devices. Applying the manufactured EBG and manipulator, in vacuum chamber the works on simulating the repair of a spacecraft’s section of aluminum 2219 alloy were carried out. The obtained results of studying the structure and mechanical characteristics and also sealing of welds confirmed the high quality of welded joints and a reliability of the technology for repairing a damaged fragment of a spacecraft's body using electron beam welding.

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New electron beam gun for welding in space

Cited by 15 publications

References 14 publications

Research on Cold Roll Forming Process of Strips for Truss Rods for Space Construction

Research on Cold Roll Forming Process of Strips for Truss Rods for Space Construction

Simulation and analysis of mechanical properties of cold-formed lock-seam of truss rods for on-orbit construction

Some Issues of Repairing Manned Space Vehicles in Outer Space Using Electron Beam Welding

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