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How to Make a Rocket - CNC Machining and Stir Welding vs Conventional welding
Citation SmarterEveryDay
How to Make a rocket - 9-11-2023 Here We show you how to make a rocket. A tour of the rocket factory.
I recall launching those model rockets in 6th grade elementry school into orbit. O the memories.. This blog post is going to go over much larger Rockets built by United Launch Alliance. They partner with Boeing, Lockheed, and NASA.
United Launch Alliance, LLC (ULA) is an American aerospace company, defense contractor, and provider of launch services.
ULA develops and runs a variety of rocket vehicles that are used to launch spacecraft into orbits around the Earth and other planets in the Solar System.
In December 2006, Lockheed Martin Space and Boeing Defense, Space & Security established the business as a joint venture. The Department of Defense (DoD) and
NASA are the primary clients of United Launch Alliance (ULA).
7 foot long aluminum plates are specially imported and CNC machined just to make the booster metal and the shield that protects the engine from its own heat signature. It used 7000 grade aluminum
in an isoteric aluminum pattern. This is the machined pattern that was used because of the machining technology available.
The machines are also hand crafted along with the CNC maching for that custom edge. The isogrid is curved and then joined together into a tube. 7000 series alumninum is porus so it needs to be
anodized in a seperate
process. In the pre-anidozation process, the parts are cleaned and then inspected.
One of three acids are used for the anidozation process. Sulfuric acid or chloric acid or one on them. Some of the bubbles in the bath attach to the metal creating a corrosion resistant layer.
Sulfuric acid is used for the plating and the etching.
Stir welding is used instead of conventional welding. Stir welding uses circular motions on an overhead cyldiner that spins to weld 2 pieces of metal together. The benefit of stir welding over conventional welding is great.
Stir welding keeps the chemical properties of the original two pieces of metal. This is very important for building the pefect spacescraft. Conventional welding changes the properties of the mtal because welds are melted onto the metal
thus creating a new metal with the welding iorn and soldering material.
The head is made out of tool steel. This can withsand the over and over usage of it. All of the parts then get welded together to form the Vulcan first flight liquid oxygen tank. The first Vulcan flight will be the
Astrologic Perigrine lander which will go to the moon!
Vulvan is a 5.58 meters in diameter Rocket. Much bigger then its predcessor.
Self Reacting Vs. Circumfrential Welding
In the self reacting welding process, there is no support behind the metal. The joints are checked in an x-ray booth and a pressurized booth. On the bottom part of the spacecraft it's a 7 to 1 ratio of Aluminum to
material. However, when we move onto the upper portion of the spacecraft, it become a 1 to 1 materials ratio. The upper part of the rocket the centaur, takes the rocket all the way into space. It will use high performance
steel, not just 7000 series grade aluminum. The gore is reisitance welded. Stainless steel dyes are used to be streched and cutt for the gore dome.
Centaur is machined and then welded. A booster is typically 80 percent mass fraction. Centaur it the highest performance upper stange ever at 90 percent mass fraction.
In chemistry and science, the mass fraction of a substance within a mixture is the ratio
(alternatively denoted) of the mass of that substance to the total mass of the entire mixture being made. Ring stress is the issue there. It's the oppposite of a
bulk buckling problem. It's not axial stress. You can think of it as a longitudial problem. The material is half the diameter of a dime. Its so think that it can't be stir welded. it has to be friction welded the
conventional welding method.
A strategic business partnership was made to bring the payload manufacturing from Switzerland to Amwerica. Vulcan's payloads are interchangable with the previous Atlas model. The United Launch Alliance has done 20 trips to
Mars already and plans on more.
Disposable Launch Platforms
Utilizing the disposable launch platforms Delta IV Heavy, Atlas V, and, up to 2018, the medium-lift Delta II, ULA offers launch services. Satellites for communications, national security, and weather have all been
launched using the Atlas, Delta IV Heavy, and retired Delta IV launch vehicles. Additionally, ULA launches business satellites. The two surviving launch vehicles from ULA will be retired and replaced by Vulcan Centaur.
The Atlas 5 has a 5 liter payload configuration. The Decataur is a three core rocket. The Vulcan is a 5.4 meter diameter rocket. It's a bit bigger than Delta. It can take 6 SRB's for takeoff power. It has 30 percent
more lift cabability then the previous three core beast.
ITAR International Traffic in Arms Regulations
This organization regulates rocket information because they use a similar technology for ballistic missiles. Therefoe the tour in this video won't show all of the processess.
BIO About the Author: Joseph P Fanning
Joe studied at Harvard. He owns Joepfanning.com and blogs alot about cool things and stuff. He co owns Business Process Automation
Phone - 201 334 8743
Email - Joe's App email
Suffolk County LI New York 11772 Bergen County NJ Programmer
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