The proposed technology will enable the creation of processing maps to characterize the solid-state joining of metals by thermal stir welding. The closed-loop temperature control system (applicable to other types of stir welding) will allow higher fidelity, stir welding of alloys of interest to NASA for manufacturing space craft and heavy lift vehicles. The analytical simulation of the stir welding process will enable more rapid and less costly formation of processing maps of a given material. The control system and analytical simulation combined will enable formation of a processing map for Haynes 230 (the alloy of choice by NASA for the J2X nozzsle extension) and establishment of a rapid process qualification methodology for thermal stir welded components.
The advancement of stir welding technologies has application well beyond NASA applications. It is envisioned this technology will become important to the Navy for ship building applications, as well as to the larger commercail ship building industry for construction of ship hulls and superstructure. The process will also be useful to fabrication of large tankage and piping for the chemical processing and transporation industry.
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