Friction Stir Welding (FSW) Reusable Launch Vehicle (RLV) Manufacturing (FSW-ACO)

Spirit AeroSystems, in collaboration with Marshall Space Flight Center, will investigate Friction Stir Welding (FSW) technologies that have been employed in the passenger jet industry and will enable damage tolerant structures and improve the life and durability of a space launch system. The following approaches will be explored via advanced materials and processing techniques: (1) Stringers will be joined to milled pad-ups utilizing a refill friction stir welding (RFSSW) process, (2) Sinusoidal FSW path profiles for panel joints to resist crack propagation, and (3) Robust and repeatable FSW tool design techniques necessary for panels and stringer joints. These FSW technologies will be evaluated for manufacturing of a damage tolerant reusable space launch vehicle. The team will also investigate opportunities to develop damage tolerant robust panel/panel FSW joint that may be better than the dual path sinusoidal FSW concept. The technical approach is to investigate Tee FSW process and evaluate the feasibility and benefits of counter rotational double pass sinusoidal FSW panel joint. A panel section will be produced via two (2) FSW techniques: (1) Tee FSW Process and (2) Sinusoidal FSW Joint. Four (4) Skins will be manufactured at Spirit, Inc. with stringer landings and Sinusoidal FSW joint pad-ups according requirements identified in FSW Tee Joint procedure qualification record (PQR) and Sinusoidal FSW PQR. NASA will produce FSW Tee joints according to the weld procedure specification (WPS) for all four panels. Stringer and skin gauges will be designed by Spirit from material properties found from the PQR. NASA will weld the panels together with sinusoidal FSW WPS.

Friction Stir Welding (FSW) offers several benefits when used in aerospace applications: Lightweight Structures: FSW allows for the creation of lightweight, high-strength joints, making it well-suited for aerospace components. The process produces minimal heat-affected zones and reduces the risk of distortion and weakening of materials. Reduced Defects: FSW is a solid-state welding technique, which means it doesn't involve melting the materials. This results in fewer defects, such as porosity and solidification cracks, which are common in fusion welding methods. Improved Mechanical Properties: FSW typically produces welds with improved mechanical properties, including higher tensile and fatigue strength. Low Heat Input: FSW generates less heat compared to traditional welding processes, reducing the risk of thermal distortion and metallurgical changes in the base materials. This is critical for maintaining the integrity of aerospace components. Environmental Benefits: FSW produces minimal fumes, emissions, and waste, making it more environmentally friendly compared to certain other welding methods. Consistency: FSW provides a high degree of consistency and repeatability in weld quality, which is essential for ensuring the reliability of aerospace components. The symbiotic collaboration between aeronautical and aerospace fields will provide a unique perspective to each and provide solutions and benefits from their mutual objectives. The aerospace field will gain understanding of damage tolerance beyond one life cycle, extending their missions deeper into space. The aeronautical field will gain the technology of friction stir welding, currently only used on aerospace products, and the development of refill friction stir spot welding will enable new skin-stiffener options for future NASA misssions. Overall, the benefits of FSW, such as lightweight construction, improved mechanical properties, and reduced defects, make it an attractive option for a variety of aerospace applications, including the fabrication of aircraft structures, rocket components, and spacecraft.

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.