Lockheed Martin weld engineer Troy Alexander inspects the clamps on the tool in preparation for the final weld on the Orion spacecraft. The vehicle was inverted in the tool for this weld. Nondestructive evaluations will validate the strength and integrity of the weld before the spacecraft is prepped for testing in flight-like environments, including static vibration, acoustics and water landing tests.
LOCKHEED MARTIN PROGRAM UPDATE
The Orion crew exploration vehicle took shape as the two halves of the crew module were fused together at NASA’s Michoud Assembly Facility in New Orleans, La. The Lockheed Martin Orion team welded the forward cone assembly to the aft barrel assembly using the next generation friction stir weld process. The 445-inch long weld is the longest such weld of its kind and will ensure optimal structural integrity for the harsh environments of space flight.
The completion of the crew module welds marked another key milestone for the Orion crew exploration vehicle, completing the structural framework of the spacecraft. All welds have met stringent quality requirements without any rework required. Prior to flight testing, this crew module will be tested on the ground in flight-like environments, including static vibration, acoustic, and water landing tests. Results will be used to correlate sizing models for all subsystems on the vehicle.
Orion weld operations take place on a Universal Weld System II (UWS II) that includes a 22-foot diameter turntable, a self-reacting friction stir weld head and a modular t-grid floor. The system affords virtually unlimited five-axis welding on fixture-mounted hardware. The UWS II is part of the National Center for Advanced Manufacturing, managed by the University of New Orleans Foundation in partnership with NASA and the State of Louisiana.
