Development of new and innovative welding and forming technologies and their application in the frame of the Ariane program

Paper number

IAC-15,D2,5,10,x30869

Author

Dr. Markus Kahnert, MT Aerospace AG, Germany

Coauthor

Dr. Johannes Hegels, Germany

Coauthor

Mr. David Knerr, Germany

Coauthor

Dr. Georg Heinrich, MT Aerospace AG, Germany

Coauthor

Mr. Rudolf Forster, MT Aerospace AG, Germany

Coauthor

Mrs. Isabelle Tessier, MT Aerospace AG, Germany

Coauthor

Mrs. Elisabeth Wild, MT Aerospace AG, Germany

Coauthor

Mr. Armin Steinacher, Germany

Coauthor

Mr. Alexander Hoschka, MT Aerospace AG, Germany

Year

2015

Abstract

To achieve an optimization in the competing objectives of low mass, high process robustness and cost reduction within the production of launcher components, the manufacturing processes must be regarded intensively. In the frame of the development program of Ariane 5 ME (A5ME) especially new and innovative forming and welding processes were carefully examined to integrate their advantages into the new upper stage bare tank of this launcher for an efficient production compared to long term established manufacturing processes.

Different development programs were carried out comprising the relevant aspects of these welding and forming technologies. The investigated forming processes spinforming and shot peenforming provide potentials in the production of net-shape parts which eliminate the mechanical rework after forming and also provide high material properties. 

Advantages of the Friction Stir Welding process as a newly developed joining process for the space component manufacturing are also presented. This technology is a solid-state joining process leading to superior material properties compared to the current standard TIG welding process.

This paper will describe aspects of the development programs carried out and will especially focus on the different demonstrators and prototype parts built within these programs. The implementation of the results  into the different series production systems is the main topic. In this regard the results of the different investigations carried out on the produced parts will be presented to underline the advantages of the regarded technologies. As an outlook these results will also be rated in the frame of an Technology Readiness Level (TRL) to assess the forming and welding technologies for the described applications of A5ME and for a future use for the new launcher Ariane6.

Abstract document

IAC-15,D2,5,10,x30869.brief.pdf

Manuscript document

IAC-15,D2,5,10,x30869.pdf (🔒 authorized access only).

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