Abstract: A system and methods are provided for combining systems of an upper stage space launch vehicle for enhancing the operation of the space vehicle. Hydrogen and oxygen already on board as propellant for the upper stage rockets is also used for other upper stage functions to include propellant tank pressurization, attitude control, vehicle settling, and electrical requirements. Specifically, gases from the propellant tanks, instead of being dumped overboard, are used as fuel and oxidizer to power an internal combustion engine that produces mechanical power for driving other elements including a starter/generator for generation of electrical current, mechanical power for fluid pumps, and other uses. The exhaust gas from the internal combustion engine is also used directly in one or more vehicle settling thrusters. Accumulators which store the waste ullage gases are pressurized and provide pressurization control for the propellant tanks.

Abstract: A liquid/gas interface pressure accumulator and mechanical filter device is especially adapted for use within a propellant utilization monitoring system of a space launch vehicle. The device provides a retrofit solution for overcoming problems associated with liquid entering a pressure sensing lines and pressure noises that collectively harm the ability to accurately measure fuel and oxidizer levels. One device is attached to each fuel and oxidizer tank of the launch vehicle. Each device includes a housing and an internal sensing chamber that is used to accumulate liquid before it can enter a pressure sensing communication line connected to a pressure sensing transducer. The construction of the device also allows filtering of undesirable pressure noises due to vibration, pressure pulsations, and other vibratory events that occur during operation of the space vehicle. The device is also selectively tunable to filter out certain frequencies and frequency ranges/bands.

Abstract: A method of performing friction stir welding is provided herein. More specifically, traditional friction stir welding requires a rotatable head that is forced against a plurality of work pieces to bond the same. The rotational and normal forces generated by the friction stir welding tool are generally reacted by a backing plate, anvil, mandrel or other mechanisms, such hardware are subject to the applied forces and are often supported with additional internal supports. Conversely, a method of performing a friction stir weld is described that omits the need for such a backing member and internal supports as it is performed using a self reacting pin tool.

Abstract: A system and methods are provided for combining systems of an upper stage space launch vehicle for enhancing the operation of the space vehicle. Hydrogen and oxygen already on board as propellant for the upper stage rockets is also used for other upper stage functions to include propellant tank pressurization, attitude control, vehicle settling, and electrical requirements. Specifically, gases from the propellant tanks, instead of being dumped overboard, are used as fuel and oxidizer to power an internal combustion engine that produces mechanical power for driving other elements including a starter/generator for generation of electrical current, mechanical power for fluid pumps, and other uses. The exhaust gas from the internal combustion engine is also used directly in one or more vehicle settling thrusters. Accumulators which store the waste ullage gases are pressurized and provide pressurization control for the propellant tanks.

Abstract: A cryogenic propellant depot and sunshield are provided for operation in earth orbit to fuel or refuel other space vehicles. The sunshield is deployed to effectively mitigate solar radiation emanating from the earth and the sun thereby providing a long term storage solution for cryogenic fluids prone to boil-off. The depot has supporting subsystems to include station keeping equipment and communication equipment so that the depot can be independently controlled. Inflatable booms are used to deploy the sunshield in a desired pattern around the depot.

Abstract: A cryogenic propellant depot and sunshield are provided for operation in earth orbit to fuel or refuel other space vehicles. The sunshield is deployed to effectively mitigate solar radiation emanating from the earth and the sun thereby providing a long term storage solution for cryogenic fluids prone to boil-off. The depot has supporting subsystems to include station keeping equipment and communication equipment so that the depot can be independently controlled. Inflatable booms are used to deploy the sunshield in a desired pattern around the depot.

Abstract: A friction stir welding system is provided herein. More specifically, traditional friction stir welding requires a rotatable head that is forced against a plurality of work pieces to bond the same. The rotational and normal forces generated by the friction stir welding tool are generally reacted by a backing plate, anvil, mandrel or other mechanisms, such hardware are subject to the applied forces and are often supported with additional internal supports. Conversely, a friction stir weld system is described that omits the need for such a backing member and internal supports as it is performed using a self reacting pin tool.

Abstract: A method of performing friction stir welding is provided herein. More specifically, traditional friction stir welding requires a rotatable head that is forced against a plurality of work pieces to bond the same. The rotational and normal forces generated by the friction stir welding tool are generally reacted by a backing plate, anvil, mandrel or other mechanisms, such hardware are subject to the applied forces and are often supported with additional internal supports. Conversely, a method of performing a friction stir weld is described that omits the need for such a backing member and internal supports as it is performed using a self reacting pin tool.

Abstract: A friction stir welding apparatus is provided herein. More specifically, traditional friction stir welding requires a rotatable head that is forced against a plurality of work pieces to bond the same. The rotational and normal forces generated by the friction stir welding tool are generally reacted by a backing plate, anvil, mandrel or other mechanisms, such hardware are subject to the applied forces and are often supported with additional internal supports. Conversely, an apparatus for performing a friction stir weld is described that omits the need for such a backing member and internal supports as it is performed using a self reacting pin tool.

Abstract: A method of performing friction stir welding is provided herein. More specifically, traditional friction stir welding requires a rotatable head that is forced against a plurality of work pieces to bond the same. The rotational and normal forces generated by the friction stir welding tool are generally reacted by a backing plate, anvil, mandrel or other mechanisms, such hardware are subject to the applied forces and are often supported with additional internal supports. Conversely, a method of performing a friction stir weld is described that omits the need for such a backing member and internal supports as it is performed using a self reacting pin tool.