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#460
by
FutureSpaceTourist
on 03 Jan, 2020 09:12
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#461
by
FutureSpaceTourist
on 08 Jan, 2020 17:47
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#462
by
FutureSpaceTourist
on 01 Feb, 2020 14:33
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#463
by
FutureSpaceTourist
on 09 Feb, 2020 17:44
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https://twitter.com/copsub/status/1226566954623913984The two first tank sections for Spica I are ready to be welded into shape.
This, ladies and gentlemen, means that we'll soon be able to see Spica I grow in length in our workshop, HAB. Can you guess what HAB stands for?
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#464
by
FutureSpaceTourist
on 09 Feb, 2020 20:04
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#465
by
FutureSpaceTourist
on 16 Feb, 2020 07:22
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'tis a long video, so here are the timestamps:
01:25 Intro by Orbital Machines CEO
04:43 Orbital Machines Recap of 2019
07:27 Reveal of Functional Pump Prototype
09:39 Jacob Larsen Intro on Copenhagen Suborbitals
11:55 The "Why?" of Copenhagen Suborbitals
13:42 Who is in Copenhagen Suborbitals?
14:52 Copenhagen Suborbitals Timeline
16:26 Is Space Too Difficult?
17:27 Nexø II Launch
18:46 Being Under The Rolling Thunder of Nexø II's Engine at Sea
19:45 Reaching Space is No Longer a Dream
20:29 Turbopumps - The "Holy Grail" of Rocketry
22:29 RD-170 Turbopump vs a Wind Farm
24:12 Turbopumps in the New Space Industry
25:11 Turbo Pumps - The Classical Approach (Gas)
25:49 Turbo Pumps - The Modern Approach (Electric)
26:49 Spica Performance Increase Using a Turbopump
27:58 Advantages of Electric Turbopumps
29:15 Copenhagen Suborbitals Developments and Swirl Injector
30:17 Spica's Propellant Consumption Demonstration
31:50 Outro
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#466
by
FutureSpaceTourist
on 25 Feb, 2020 20:56
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#467
by
FutureSpaceTourist
on 26 Feb, 2020 11:17
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Dear Rocket Fans,
Last Sunday it was finally time for our home-built long-seam welder to show its worth. The propellant tanks for Spica I had to be welded. Prior to this, of course, a lot of work has been done, both in making the long-seam weld but also in fine tuning it and finding the right settings for the highest strength. For this purpose, we prepared a series of samples that were tested for strength.
[attachment 1]
Test subjects after tensile testing.
As seen there are four sets. The first is just the raw plate, so we have a basis to compare the welded items with. Next, two sets of items welded from one side and finally a set of specimens welded from both sides of the plate. The result of the tensile test is shown below.
[attachment 2]
Test data from all 12 specimens.
As can be seen, the base has a yield strength of about 633 MPa. The six samples welded on one side have a yield strength of about 620 MPa, so we have a welding factor of 0.98 here, quite respectable actually. Even better however, is the plate welded from both sides. There is little spread but the mean is around 652 MPa. Also note in the pictures above that the breakage does not occur in the weld, but in the piece above the weld. So with this welding technique we do not lose strength at all and thus it is easy to choose how to weld the propellant tanks Spica I. The tanks for this will of course be welded from both sides.
Our home-build long-seam welder is relatively simple. It consists of a fairly strong square profile at the bottom which gives strength and stiffness to the entire setup. On top is a copper rail where we can run passivation gas through a number of small holes. Across the copper rail there are two powerful jaws that are used to clamp the workpiece. Across the two jaws we have an adjustable linear guide that can hold a regular TIG handle. Feed is controlled with a computer.
[attachment 3]
From a distance it may not look like much, but it is a little wonder the guys have been building and testing the last few months. Photo: Carsten Olsen.
A Spica I propellant tank is made from a plate of 3000 x 1500 x 3 mm rolled to a diameter of 950 mm. It weighs around 100 kg, so it takes a little man power to get it lifted in place and tightened in the jaws, but it went without too much hassle. Next, of course, it must be aligned so that the two edges meet correctly and the TIG handle is adjusted so that the direction and height fit over the entire 1500 mm long piece.
Then the ends are tagged to each other every 50 mm to ensure that everything does not warp during the long welding.
[attachment 4]
Tags for every 50 mm. Notice the two powerful jaws that hold it all in place. Photo: Sarunas Kazlauskas.
And finally we could simply press the start button and watch in awe as the 1500 mm perfect weld seam appeared.
[attachment 5]
Full auto welding for the win! Notice the inlet plate on the left. It ensures that we do not melt holes at the beginning of the plate and of course need to be cut off eventually. Photo: Thomas Pedersen.
The result is quite overwhelming and not at all something we would be able to achieve with manual handheld welding, just see below.
[attachment 6]
Perfect weld seam after a bit of polishing. Photo: Sarunas Kazlauskas.
That was the inside weld of the two tanks. Next up is the outside weld. I am not too sure how our welding experts will do this but I hear rumors about propping the whole setup up on a forklift to gain the height necesarry to have the whole cylinder below the welding jig… Well, tune in next week to see more on that 🙂
https://copenhagensuborbitals.com/welding-spica-i/
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#468
by
FutureSpaceTourist
on 28 Feb, 2020 16:39
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#469
by
FutureSpaceTourist
on 04 Mar, 2020 18:11
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#470
by
FutureSpaceTourist
on 07 Mar, 2020 07:10
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#471
by
FutureSpaceTourist
on 07 Mar, 2020 16:31
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https://twitter.com/copsub/status/1236329306382614530 We've been focusing on fuel injectors as well today. In case you need any b-roll. 
twitter.com/djsnm/status/1236330665152352256
Would love that - are you still using coaxial swirl injectors?
https://twitter.com/copsub/status/1236336860873588738 Yes, we're getting a lot of them machined for 4 different BPM5 size injector assemblies to settle a BPM100 injector design. The ones in the picture are 3D printed SS, though. We also have old footage of our impinging showerhead injectors if you wish? Should I DM you a link later?
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#472
by
FutureSpaceTourist
on 08 Mar, 2020 15:09
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#473
by
FutureSpaceTourist
on 16 Mar, 2020 17:47
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https://twitter.com/copsub/status/1239619198243962881The next major step in Spica's propellant tank production are the bulkheads. A while ago we cut the piping holes on them using our homemade CNC plasma cutter. A few people now, including John here, are preparing and welding the pipe fittings to those holes. 🚀
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#474
by
FutureSpaceTourist
on 18 Mar, 2020 12:23
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#475
by
josespeck
on 20 Mar, 2020 19:14
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#476
by
FutureSpaceTourist
on 22 Mar, 2020 10:54
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#477
by
FutureSpaceTourist
on 27 Mar, 2020 18:26
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https://twitter.com/copsub/status/1243612222930198534 Since the astronaut seat prototype is nearly done, the Capsule group is moving to its shock absorption mechanism. Short, sudden spikes in G loads during parachute deployment and splashdown can be a bit uncomfortable, so these guide blocks will guide the seat under its damper.
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#478
by
FutureSpaceTourist
on 29 Mar, 2020 08:39
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#479
by
FutureSpaceTourist
on 30 Mar, 2020 18:14
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https://twitter.com/copsub/status/1244687842544168960Since we're a space program founded in the same country as @LEGO_Group, it's only natural that we use those wonderful bricks as an easy fix for a much needed tool. Here, a guide has been made for the webbing of a Spica booster drogue parachute prototype.
