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INTERNATIONAL SPACE STATION MISSIONS BY SHUTTLE SAVES 8000 LBS. PER LAUNCH BY USING NEW HIGH LITHIUM ALLOY TO CONSTRUCT EXTERNAL TANK(ET).

The problem with High lithium content Alloys 2195 is that it results in fusion welding cracks, and other defects. To repair these defects we need a new process to avoid the heat of fusion welding and the special welding techniques required to repair each individual defect. To solve this problem the area of the defect is determinately processed by a Friction(Stir) welding approach. Friction welding does generate a small amount of heat but not enough to melt the alloy. It causes the alloy to enter into a plastic state. The defect is eliminated by this process in a uniform manner. ALS personnel developed the welding schedules and the Logic to make the process work. The techniques are still in use beyond production of the ET, and are still used by SpaceX, Boeing, and NASA.

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