Abstract: A lightweight structure for a vehicle, in particular an aircraft, comprises a longitudinal member with a base web, which has a first busbar on a contact surface, and a cross member with a central web and a cross web extending transversely to the central web, the cross web being a first connecting conductor which extends in the area of a first end section of the cross member on a first surface and a second surface of the cross web oriented opposite to this, and a second connection conductor track which extends separately from the first connection conductor track at least on the first surface of the cross web. The cross member extends transversely to the longitudinal member and the cross member is connected at the first end section to the base member in such a way that the first connection conductor track is in contact with the first busbar of the base member.

Abstract: In one embodiment, systems and methods include using a battery to provide electrical charge to a vehicle. The battery comprises a first half of a housing coupled comprising one or more air vents and an anode disposed at least partially within the first half of the housing. The battery further comprises a second half of the housing comprising one or more air vents, wherein the anode extends from the first half of the housing and into the second half of the housing. The battery further comprises a pair of cathodes disposed within the second half of the housing, wherein the pair of cathodes extends from the second half of the housing and into the first half of the housing, wherein the anode is disposed between the pair of cathodes, wherein there is a gap between the anode and each one of the pair of cathodes.

Abstract: A friction stir processing system can include a rotatable die assembly. The rotatable die assembly can include a die body and a plurality of die segments. The die body includes a die base and a die stem. The die stem extends axially from the die base, the die stem defines an extrusion cavity, and the die body is formed from a first material. The plurality of die stems are coupled to the die stem. The plurality of die segments are disposed around the extrusion cavity to collectively form a die surface opposite to the die base. The plurality of die segments are formed from a different material than the die body.

Abstract: A strut-and-node truss design that is applicable to space frame structure designs can be assembled with using robotic (semi-autonomous and/or fully autonomous) or telerobotic assembly/joining. The assembly system can include a storage module that includes the components for assembly and an assembly module that can retrieve and assembly the components. The resulting truss structure can be connected to an antenna (e.g., carried by the storage module) for deployment. The assembly module can be operated repeatedly in conjunction with additional resupply systems that provide additional components for assembly.

Abstract: A strut-and-node truss design that is applicable to all space frame structure designs can be made with using robotic (semi-autonomous and/or fully autonomous) or telerobotic assembly/joining. Nodes can include a 2-dimensional weld path in an effort to reduce the complexity of having to weld in 3-dimensions. Furthermore, each strut to node connection can be concentrated in a small area where each weld can be performed robotically from a fixed position that only requires the robotic weld head to swivel in a small operating window to reach each joint.

Abstract: A friction stir processing system can include a rotatable die assembly. The rotatable die assembly can include a die body and a plurality of die segments. The die body includes a die base and a die stem. The die stem extends axially from the die base, the die stem defines an extrusion cavity, and the die body is formed from a first material. The plurality of die stems are coupled to the die stem. The plurality of die segments are disposed around the extrusion cavity to collectively form a die surface opposite to the die base. The plurality of die segments are formed from a different material than the die body.

Abstract: A continuous feed method for friction stir processing includes continuously feeding a tubular material having a first grain microstructure from a bulk source into a processing chamber, and forcing the tubular material between a die and a textured end portion of a mandrel as the tubular material is advanced through the chamber. The continuous feed method further includes rotating the mandrel within the tubular material while forcing the tubular material across the textured end portion to friction stir process the tubular material and transform a structure of the tubular material from the first grain microstructure to a second grain microstructure. The second grain microstructure is a finer equiaxed grain microstructure than the first grain microstructure. The method further includes converting the tubular material having the second grain microstructure into a stiffened sheet form.

Abstract: A manufacturing system includes a tension-wound system having a feedstock system and a shape fixture. The tension-wound system is configured to feed a feedstock from the feedstock system and to wind the feedstock under tension in successive layers around the shape fixture to allow the feedstock to form a component having a shape represented by the shape fixture. The manufacturing system includes a solid-state joining tool configured to additively join the successive layers of the feedstock. In a spiral tension-winding process, with a continuously-fed strip of aluminum feedstock around a piece of tooling, the feedstock can be friction stir welded and additively joined in successive layers to produce a large, near-net structure.

Abstract: A strut-and-node truss design that is applicable to all space frame structure designs can be made with using robotic (semi-autonomous and/or fully autonomous) or telerobotic assembly/joining. Nodes can include a 2-dimensional weld path in an effort to reduce the complexity of having to weld in 3-dimensions. Furthermore, each strut to node connection can be concentrated in a small area where each weld can be performed robotically from a fixed position that only requires the robotic weld head to swivel in a small operating window to reach each joint.

Abstract: A process of producing shell and tube heat exchangers where the ends of the tubes are secured to a tube sheet while reacting applied FSW forces without introducing a crevice or local deformation near the ends of the tubes. In particular, an interference fit is used to lock the ends of the tubes into the tube sheet without flaring or expanding the tube ends. A FSW process is then used to weld the ends of the tubes to the tube sheet.

Abstract: A process of producing shell and tube heat exchangers where the ends of the tubes are secured to a tube sheet while reacting applied FSW forces without introducing a crevice or local deformation near the ends of the tubes. In particular, an interference fit is used to lock the ends of the tubes into the tube sheet without flaring or expanding the tube ends. A FSW process is then used to weld the ends of the tubes to the tube sheet.

Abstract: A hybrid plate-fin heat exchanger for exchanging heat between a first fluid and a second fluid is disclosed. The hybrid plate-fin heat exchanger comprises a plurality of plates, each of which comprises channels for conveying the first fluid. Fins are brazed onto each plate, wherein the fins define a plurality of flow channels for the second fluid. The plates are joined to one another via friction-stir welding in such a way that the brazed regions are fluidically isolated from the first fluid during operation. As a result, the heat exchanger is suitable for use in applications that use a first fluid, such as seawater or geothermal fluid, which is corrosive for the brazed regions.

Abstract: A process that uses friction stir welding to connect a tube, for example a thin gauge tube having a wall thickness of about 2.54 mm (0.100 inch) or less, to another element, such as a tube sheet of a heat exchanger. The process employs a tubular anvil that is installed into the end of the tube and which, in one embodiment, can provide material during the friction stir welding process. After the weld is complete, the weld zone between the tubular anvil and the tube is machined away and the anvil tube removed.

Abstract: A heat exchanger comprising a plurality of plates that are demountably attached to a frame is disclosed. Each plate comprises a plurality of channels for conveying a primary fluid through the heat exchanger. The frames are arranged in the frame so that spaces between adjacent frame pairs define conduits for conveying a secondary fluid through the heat exchanger. The plates are mounted in the frame so that they can be individually removed from the frame. Further, each of the channels is fluidically connected to input and output ports for the primary fluid by detachable couplings. As a result, heat exchangers in accordance with the present invention are more easily repaired or refurbished than prior-art heat exchangers.

Abstract: A process of producing shell and tube heat exchangers where the ends of the tubes are secured to a tube sheet while reacting applied FSW forces without introducing a crevice or local deformation near the ends of the tubes. In particular, an interference fit is used to lock the ends of the tubes into the tube sheet without flaring or expanding the tube ends. A FSW process is then used to weld the ends of the tubes to the tube sheet.

Abstract: A process of producing shell and tube heat exchangers where the ends of the tubes are secured to a tube sheet while reacting applied FSW forces without introducing a crevice or local deformation near the ends of the tubes. In particular, an interference fit is used to lock the ends of the tubes into the tube sheet without flaring or expanding the tube ends. A FSW process is then used to weld the ends of the tubes to the tube sheet.

Abstract: A process of producing shell and tube heat exchangers where the ends of the tubes are secured to a tube sheet while reacting applied FSW forces without introducing a crevice or local deformation near the ends of the tubes. In particular, an interference fit is used to lock the ends of the tubes into the tube sheet without flaring or expanding the tube ends. A FSW process is then used to weld the ends of the tubes to the tube sheet.

Abstract: Shell-and-tube heat exchangers that utilize one or more foam heat transfer units engaged with the tubes to enhance the heat transfer between first and second fluids. The foam of the heat transfer units can be any thermally conductive foam material that enhances heat transfer, for example graphite foam. These shell-and-tube heat exchangers are highly efficient, inexpensive to build, and corrosion resistant. The described heat exchangers can be used in a variety of applications, including but not limited to, low thermal driving force applications, power generation applications, and non-power generation applications such as refrigeration and cryogenics. The foam heat transfer units can be made from any thermally conductive foam material including, but not limited to, graphite foam or metal foam. In an embodiment, the heat exchanger utilizes tubes that are twisted around a central foam heat transfer unit.

Abstract: A process that uses friction stir welding to connect a tube, for example a thin gauge tube having a wall thickness of about 2.54 mm (0.100 inch) or less, to another element, such as a tube sheet of a heat exchanger. The process employs a tubular anvil that is installed into the end of the tube and which, in one embodiment, can provide material during the friction stir welding process. After the weld is complete, the weld zone between the tubular anvil and the tube is machined away and the anvil tube removed.

Abstract: Fluid conveying pipes and processes of forming such pipes using friction stir welding. The fluid conveying pipes are formed from a pipe section that includes a first barrel coaxially and concentrically disposed within a second barrel. The first barrel and the second barrel are each formed from one or more sections or plates where longitudinal extending facing edges of the plates are friction stir welded (FSW) together along a seam(s) that extends longitudinally from the first end to the second end thereof. A plurality of the pipe sections can be connected together end to end using circumferential FSW seams to form a pipe.