Systems and methods for bonding objects using energetic welding

Systems and methods for bonding objects using energetic welding are disclosed. A representative system includes a launch vehicle portion, one or more landing support elements positioned to support the launch vehicle portion when the launch vehicle portion lands on a landing surface, and a bonding device carried by at least one of the landing support elements and configured to form a bond between the bonding device and the landing surface when the launch vehicle portion is on the landing surface. The bond may include a weld. A further representative system includes a bonding device with an energetic material and an anchor element, wherein activating the energetic material deforms the anchor element onto a landing surface to form a weld between the bonding device and the landing surface. A representative method includes automatically bonding a portion of a launch vehicle to a landing surface in response to landing.

TECHNICAL FIELD

The present disclosure is directed generally to systems and methods for bonding objects using energetic welding. Representative aspects of the present disclosure relate to automatically bonding a landing support element of a reusable launch vehicle booster stage to a surface upon landing the booster stage on the surface.

BACKGROUND

Rockets have been used for many years to launch human and non-human payloads into orbit. Such rockets delivered the first humans to space and to the Moon, and have launched countless satellites into the Earth's orbit and beyond. Such rockets are used to propel unmanned space probes to deliver structures, supplies, and personnel to the orbiting International Space Station.

Rocket manufacturers continually strive to reduce the cost of launching a payload into space or the upper atmosphere. One approach for reducing such costs is to retrieve one or more stages of a rocket, such as one or more booster stages used to propel the rocket. In a particular approach, a rocket stage is landed vertically (e.g., tail-down or nozzle-down) and then refurbished for launch. One drawback with this approach is that it may be difficult to land the rocket stage in an exact position, such as a position that has been configured to secure the rocket stage in a vertical orientation. In yet another particular approach, a rocket stage is landed vertically on a floating platform (such as a sea-going platform). A floating platform may rock and sway, which presents the additional challenge of keeping the rocket stage upright after landing. Additionally, a rocket stage that has landed on a surface but has not been secured, including a surface on a floating platform, presents a potential safety hazard for workers and equipment nearby. Accordingly, one challenge associated with landing a vehicle (such as a rocket stage) vertically is ensuring the vehicle is adequately supported after landing. Aspects of the present disclosure are directed to addressing this challenge.

DETAILED DESCRIPTION

Embodiments of the technology disclosed herein are directed generally to systems and methods for bonding objects using energetic welding and energetic materials. Several embodiments of the present technology are directed to securing a portion of a launch vehicle (such as a booster stage) to a landing surface, but the present technology can be implemented in other systems in which rapid bonding between two objects is desired.

A representative system includes a launch vehicle portion, one or more landing support elements carried by the launch vehicle portion and positioned to support the launch vehicle portion upon landing on a landing surface, and a bonding device carried by at least one of the landing support elements and configured to form a weld between the bonding device and the landing surface when the launch vehicle portion is on the landing surface. A further representative system includes a bonding device having an energetic material, and an anchor element having a layer of metal material, wherein activating the energetic material deforms the layer of metal material onto the landing surface to form a weld between the bonding device and the landing surface. A representative method includes automatically welding a portion of a launch vehicle to a landing surface after landing (e.g., in response to landing), using an energetic material.

Several details describing structures and processes that are well-known and often associated with energetic materials and launch vehicles are not set forth in the following description to avoid obscuring other aspects of the disclosure. Moreover, although the following disclosure sets forth several embodiments, several other embodiments can have different configurations, arrangements, and/or components than those described in this section. In particular, other embodiments may have additional elements, and/or may lack one or more of the elements described below with reference toFIGS.1-6.

Many embodiments of the technology described below may take the form of computer- or controller-executable instructions, including routines executed by a programmable computer or controller. Those skilled in the relevant art will appreciate that the technology can be practiced on computer/controller systems other than those shown and described below. The technology can be embodied in a special-purpose computer, controller, or data processor that is specifically programmed, configured, or constructed to perform one or more of the computer-executable instructions described below. Accordingly, the terms “computer” and “controller” as generally used herein refer to any data processor and can include Internet appliances and hand-held devices (including palm-top computers, wearable computers, cellular or mobile phones, multiprocessor systems, processor-based or programmable consumer electronics, network computers, mini computers, and the like). Information handled by these computers can be presented at any suitable display medium, including an LCD.

The technology can also be practiced in distributed environments, where tasks or modules are performed by remote processing devices that are linked through a communications network (e.g., a wireless communication network, a wired communication network, a cellular communication network, the Internet, and/or a short-range radio network such as Bluetooth). In a distributed computing environment, program modules and/or subroutines may be located in local and remote memory storage devices. Aspects of the technology described below may be stored and/or distributed on computer-readable media, including magnetic or optically readable or removable computer disks, as well as distributed electronically over networks. Data structures and transmissions of data particular to aspects of the technology are also encompassed within the scope of the embodiments of the technology.

FIG.1is a schematic diagram illustrating a representative mission profile of an aerospace system including a launch vehicle, in which at least a portion of the launch vehicle lands in a controlled manner on a surface. A launch vehicle100can include multiple portions (e.g., stages), such as a first or booster stage110and one or more second or upper stages120. The launch vehicle100can be a space launch vehicle for carrying humans or cargo to space or it can be a launch vehicle for moving humans or cargo within the Earth's atmosphere. Accordingly, although reference may be made to orbital space, embodiments of the present technology may be used with portions (e.g., stages) of launch vehicles that carry out suborbital missions.

Although the upper stage120is stacked on top of the booster stage110in the illustrated mission profile, in other embodiments the launch vehicle100and variations thereof can have other configurations without departing from the present disclosure. For example, the upper stage120and the booster stage110can be positioned side-by-side and attached to each other during ascent with a suitable separation system. In another example, two or more booster stages110or variations thereof can be positioned around the upper stage120in a “strap-on” type configuration. Accordingly, the present disclosure is not limited to the particular launch vehicle configuration illustrated inFIG.1. Although embodiments of the present technology may be applied to any of the portions (e.g., stages) of the launch vehicle100, such that embodiments of the present technology may secure any of the portions to a surface, a representative embodiment is described in more specific detail below with regard to the booster stage110. The booster stage110includes a forward end130and one or more rocket engines140(including one or more exhaust nozzles) positioned toward an aft (tail) end150.

In the illustrated example, the launch vehicle100takes off from a coastal or other land-based launch site155and then turns out over a body of water160(such as an ocean). At some point, such as after a high-altitude booster engine cutoff (BECO) operation, the booster stage110separates from the second (e.g., upper) stage120and continues along a ballistic trajectory165. The second (e.g., upper) stage120can include one or more engines170that ignite and propel the second stage120into a higher trajectory175for orbital insertion or other destinations or activities.

The booster stage110reenters the Earth's atmosphere before or after reorienting so that the aft end150is pointing in the direction of motion (tail-first). The booster stage110descends toward a landing platform180, which can be a floating (e.g., sea-going) platform, although it can alternatively be a fixed platform on land (for example, the mission can take place entirely over land, or over a combination of land and water). The booster stage110can land tail-first on the landing platform180using thrust from the one or more rocket engines140. The booster stage110can carry one or more landing support elements190, which can include suitable shock-absorbing landing gear (e.g., one or more landing legs). The landing support elements190can support the booster stage110in an upright position after landing. As described in additional detail below, in response to landing, upon landing, or after landing (such as shortly after landing), the landing support elements190can be bonded to the landing platform180in accordance with embodiments of the present disclosure.

The foregoing mission profile is provided for example only and does not limit application of the present technology. For example, embodiments of the present technology can be used to secure any portion (e.g., stage) of a launch vehicle after the portion lands in any orientation on any suitable landing support element190, with or without thrust (e.g., with a parachute to control the rate of descent).

FIG.2illustrates a partially schematic view of a portion of a launch vehicle (e.g., the booster stage110) after landing on a landing surface200, which can be a landing surface200on the landing platform180. The landing surface200can include a metal material, such as steel or another suitable metal material. For example, the landing surface200can include one or more plates of steel with a thickness of approximately 1.5 inches (or another suitable thickness), spanning an area positioned to receive the portion of the launch vehicle. One or more (e.g., all) of the landing support elements190can include a bonding device210positioned to contact the landing surface200as the launch vehicle (e.g., the booster stage110) lands.

Upon landing, each bonding device210can automatically bond (e.g., weld) the booster stage110(via the one or more landing support elements190) to the landing surface200. Although five landing support elements190are visible inFIG.2, and although the landing support elements190are illustrated as being oriented at an oblique angle A relative to the landing surface200, embodiments of the present technology can implement more or fewer landing support elements190and/or the landing support elements190can be oriented at other angles A relative to the landing surface200, such as an approximately 90-degree angle (e.g., the landing support element190can be generally vertical).

FIG.3Aillustrates a partially schematic side cross-sectional view of a bonding device210carried by a landing support element190and configured in accordance with embodiments of the present technology.FIG.3Billustrates a partially schematic perspective cross-sectional view of the bonding device210carried by the landing support element190shown inFIG.3A. With reference to bothFIGS.3A and3B, the landing support element190can include a foot pad300, which may contact the landing surface200upon landing. The foot pad300can carry the bonding device210. In some embodiments, the landing support element190can directly carry the bonding device210, without a foot pad300. The bonding device210can include an anchor element310releasably attached to the foot pad300(or attached directly to the landing support element190) via one or more releasable fastening elements320, such as bolts or other suitable releasable fasteners.

The anchor element310is shaped and configured to carry an energetic material330. For example, the anchor element310can include an upper cavity340for receiving the energetic material330. At the bottom of the upper cavity340is a layer350of metal material configured to be positioned between the energetic material330and the landing surface200. The anchor element310can also include a lower cavity360, which forms a gap370between the layer350of metal material and the landing surface200. An initiation device380is positioned in or near the energetic material330and is configured to initiate or activate the energetic material330.

In some embodiments, system(s) implementing the bonding device210can include a controller382(which is schematically illustrated inFIG.3A) configured to receive instructions to initiate the initiation device380or programmed with instructions that, when executed, carry out operations associated with the bonding device210. The launch vehicle can carry the controller382or the controller382can be separate from the launch vehicle, with suitable wireless or wired connections for communicating with the initiation device380.

Activation of the energetic material330produces pressure against the layer350of metal material, which causes the layer350to deform onto the landing surface200(i.e., the layer350impacts the landing surface200), causing the gap370to generally close. The impact of the layer350onto the landing surface200causes the layer350of metal material to bond (e.g., weld) to the landing surface200. When the layer350of metal material is bonded to the landing surface200, the bonding device210is bonded to the landing surface200, and accordingly, the landing support element190is bonded to the landing surface200. Bonding the landing support element190to the landing surface200enhances stability of the landed rocket, especially on a floating platform and/or in windy conditions. Operators can release the releasable fastening elements320to free the landing support element190and/or the foot pad300from the bonding device210to free the landing support element190from the landing surface200.

The anchor element310can be formed with multiple pieces, or it can be formed as an integral element. The anchor element310can include a plate portion383having a first or upper side385facing the landing support element190, and a second or lower side387opposite the upper side385and positioned to face the landing surface200. The anchor element310can further include a perimeter or ring portion390positioned on the upper side385of the plate portion383. The ring portion390can form the upper cavity340for receiving the energetic material330. The plate portion383can include the layer350of metal material positioned beneath the upper cavity340. The lower side387of the plate portion383can include or bound the lower cavity360, which extends into the plate portion383and forms the gap370between the layer350of metal material and the landing surface200. In some embodiments, the lower side387can extend beyond the foot pad300(e.g., below the lowest portion of the foot pad300) such that the lower side387contacts the landing surface200and the foot pad300does not contact the landing surface200. In other embodiments, the lower side387can be generally flush with the outwardly positioned surfaces of the foot pad300such that the lower side387and the foot pad300contact the landing surface200upon landing.

In some embodiments, energy from activation of the energetic material330can be directed upward in addition to downward toward the layer350. Accordingly, in some embodiments, the landing support element190can be generally open above the energetic material330.

In some embodiments, the anchor element310can have an overall width or diameter of approximately 14 inches. In some embodiments, the gap370can span a distance of approximately one-fourth of an inch between the bottom of the layer350of metal material and the landing surface200(in other words, the gap370can extend into the anchor element310by a distance of approximately one-fourth of an inch). Although specific dimensions are provided for context and/or to indicate representative embodiments, various further embodiments can have other sizes.

In some embodiments, the layer350of metal material can be formed with a high elongation steel material such as SAE 304 stainless steel. In some embodiments, other components of the anchor element310can be formed with the same material as, or a different material from, the layer350of metal material. Although representative embodiments include the layer350being formed with SAE 304 stainless steel because of its generally high elongation properties that facilitate a strong bond (e.g., a weld) and because of its general resistance to corrosion, other embodiments can include other materials suitable for bonding together under the pressure from an energetic material. For example, although soft metals are preferable, various embodiments can include any metal materials that can be rapidly pressed together to form a bond (e.g., a weld). In some embodiments, the landing surface200can also be formed with SAE 304 stainless steel. In further embodiments, the landing surface200can be formed with A36 steel and it can be ground (e.g., polished) to improve the bond.

The energetic material330can include an ammonium nitrite and fuel oil (ANFO) material, but further embodiments can include other suitable energetic materials. The initiation device can include a booster (such as PETN, RDX, HMX, or another suitable material) and a device or material for activating the booster, and/or another initiation device suitable for activating the energetic material330.

FIG.4Aillustrates a partially schematic side view of a bonding device400carried by a landing support element410and configured in accordance with further embodiments of the present technology.FIG.4Billustrates a partially schematic perspective view of the bonding device400carried by the landing support element410shown inFIG.4A. With reference toFIGS.4A and4B, the bonding device400can be attached to a side or edge of the landing support element410. In some embodiments, a plurality (such as two) bonding devices400can be positioned on various (e.g., opposing) sides of the landing support element410.

The bonding device400can include an anchor element420configured to support an energetic material430. In some embodiments, the anchor element420can be generally L-shaped, having an upright portion440attached to the landing support element410and a horizontal portion450extending from the upright portion440. The horizontal portion450can include and/or can be formed with a layer of metal material, which can be similar to the layer350of metal material described above with regard toFIGS.3A and3B. The energetic material430can be linearly (such as rectangularly) shaped, or it can have other forms.

The anchor element420can be positioned on the landing support element410such that the horizontal portion450is spaced apart from the landing surface200upon landing, forming a gap460between the horizontal portion450and the landing surface200. Activation of the energetic material430produces pressure that deforms the horizontal portion450downward, such that the horizontal portion450impacts the landing surface200and bonds (e.g., welds) to the landing surface200. Operators can release the anchor element420from the remainder of the landing support element410(for example, by releasing fasteners or cutting the anchor element420) to free the portion of the launch vehicle (e.g., the booster stage) from the landing surface200. In some embodiments, energy from activation of the linearly-shaped energetic material430can be directed upward or outward, although in either situation, the energy is directed away from the landing support element410.

In some embodiments, system(s) implementing the bonding device400can include the controller382(which is schematically illustrated inFIG.4A) configured to receive instructions to activate the energetic material430(for example, with an initiation device) or programmed with instructions that, when executed, carry out operations associated with the bonding device400.

FIG.5illustrates a partially schematic side cross-sectional view of a bonding device500carried by a landing support element510and configured in accordance with further embodiments of the present technology. The bonding device500includes an anchor element520and an energetic material530supported on the anchor element520. The anchor element520is attached to a bottom portion of the landing support element510(e.g., with one or more fasteners535) such that the anchor element520can be between the landing support element510and the landing surface200upon landing. In some embodiments, the anchor element520includes a plate portion540and a ring portion550extending from the plate portion540. The plate portion540and the ring portion550can be arcuate in shape (such as circular) or they can have a polygonal shape or another suitable shape. In a particular representative embodiment, the ring portion550is an annular ring extending from the plate portion540. The ring portion550includes a bottom surface560that is recessed away from a lowermost surface570of the plate portion540to form a gap580between the ring portion550and the landing surface200. The ring portion550can include and/or can be formed with a layer of metal material, which can be similar to the layer350of metal material described above with regard toFIGS.3A and3B.

In some embodiments, the ring portion550can have a thickness T of approximately 0.5 inches and the gap580can span a distance of approximately one-fourth of an inch between the bottom surface560of the ring portion550and the landing surface200(or the lowermost surface570of the plate portion540). Although specific dimensions are provided for context and/or to indicate representative embodiments, various further embodiments can have other sizes.

Upon activation of the energetic material530, pressure deforms the ring portion550downward to cause the ring portion550to impact the landing surface200, which causes the ring portion550to bond (e.g., weld) to the landing surface200. Accordingly, activation of the energetic material530bonds the anchor element520to the landing surface200. In some embodiments, the energetic material530can be activated in one location, causing two activation fronts to travel around the ring portion550. In some embodiments, the energetic material530can be activated in multiple locations.

Operators can release the anchor element520from the remainder of the landing support element510(for example, by releasing the fasteners535or cutting the anchor element520) to free the launch vehicle from the landing surface200. In some embodiments, energy from activation of the energetic material530can be directed upward or outward, although in either situation, the energy is directed away from (or at least not directed towards) the landing support element510.

In some embodiments, system(s) implementing the bonding device500can include the controller382(which is schematically illustrated inFIG.5) configured to receive instructions to activate the energetic material530(for example, with an initiation device) or programmed with instructions that, when executed, carry out operations associated with the bonding device500.

Although representative embodiments of the present disclosure include the foregoing shapes and configurations of bonding devices, other embodiments include other shapes and configurations suitable for deforming a layer of metal onto the landing surface200while facilitating removal of the launch vehicle from the bonding device and while allowing energy from the activation of the energetic material to be directed away from the landing support elements and/or the remainder of the launch vehicle. Gaps between the metal material of the bonding devices and the landing surface (such as the gaps370,460,580described above) facilitate momentum and acceleration of the metal material toward the landing surface to impact the landing surface in response to activation of the energetic material, which further facilitates a strong bond between the metal material and the landing surface. In some embodiments, the gaps may be at least partially filled (e.g., fully filled) with a medium between the metal material and the landing surface. For example, such a medium may include a collapsible material such as foam. Such a medium may be configured to crush, burn, melt, evaporate, or otherwise be obliterated upon activation of the bonding devices.

FIG.6is a flow chart illustrating a method for automatically bonding and subsequently removing a portion of a launch vehicle from a landing surface, in accordance with embodiments of the present technology. The controller382(seeFIGS.3A,4A, and5) can carry out some or all steps of the method, or another controller or system can carry out the method. Beginning in block600, the launch vehicle (or portion thereof, such as a booster stage) is in a pre-flight condition, or is in forward flight, or is in a tail-down orientation ready for landing. In block610, the bonding device610is armed. In block620, the controller382(which may be carried by the launch vehicle or separate from the launch vehicle) determines if the portion of the launch vehicle has made contact with the landing surface (e.g., touched down), and/or whether the propulsion systems have been shut off. In response to touchdown and/or shutoff of the propulsion systems, the controller382can initiate function of the bonding device (e.g., activation of the energetic material), in block630. In some embodiments, the controller382can delay fora period of time after touchdown and/or propulsion shutoff before activating the energetic material. Activating the energetic material causes the bonding device to bond to the landing surface, as described above.

In block640, crew can remove the portion of the launch vehicle from the bonding device, which can remain bonded to the landing surface until it is later removed and/or the landing surface is replaced. In some embodiments, removal of the portion of the launch vehicle from the bonding device can include cutting the bonding device or otherwise separating the portion of the launch vehicle from the layer of metal material that has welded to the landing surface. In some embodiments, removal of the portion of the launch vehicle can include safing procedures such as removal of propellants. In some embodiments, alternative and/or supplemental restraints can be positioned to hold the portion of the launch vehicle in place before and/or after the landing support elements are released from the bonding devices. For example, in some embodiments, releasable restraints can relieve the strain on the landing support elements and support the portion of the launch vehicle on the sea-going platform after the bonding devices have been released and the platform travels to port. The portion of the launch vehicle can be supported in an upright orientation.

One feature of several of the embodiments described above with regard toFIGS.1-6, and with other embodiments configured according to the present disclosure, is that the bonding devices can bond anywhere on the landing surface, which is useful when it is difficult or not possible to precisely position the landing portion of the launch vehicle. Another feature is that bonding can occur quickly (in some embodiments, on the order of a millisecond), which is useful in high winds and/or rough seas, and which is in contrast to slower methods of restraining something on a surface, such as fusion welding or using fasteners. Another feature is that each bonding device can provide a strong bond, such as more than 300,000 pound-force of strength, or other suitable levels. Having multiple bonding devices on a landing portion of a launch vehicle provides redundancy. For example, in the event one or more bonding devices fail, the portion of the launch vehicle may remain attached to the landing surface. Another feature is that energy from the energetic material can be directed away from other parts of the launch vehicle (including other parts of the landing support elements). In some embodiments, it may be preferable to have a clean landing surface, such as a surface without paint or corrosion, however, it is contemplated that embodiments of the present technology can create a bond even on an imperfect metal surface. Generally, embodiments of the present technology provide a rapid system and method for securing a rocket stage to a landing surface without the need for human intervention during the bonding process. This in turn provides operators with an increased level of safety. For example, operators may be safely positioned in a remote location.

From the foregoing, it will be appreciated that specific embodiments of the disclosed technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the technology. For example, the anchor element may have different shapes for accommodating different landing elements or energetic materials. In some embodiments, bonding devices can include a cover element positioned over the energetic material to protect the energetic material from environmental factors. Although landing elements and rocket components are described herein, bonding devices configured in accordance with embodiments of the present technology can be used to bond other objects together. Although specific dimensions are provided for context and/or to indicate representative embodiments, various further embodiments can have other sizes.

Certain aspects of the technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Further, while advantages associated with certain embodiments of the disclosed technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the present technology. Accordingly, the present disclosure and associated technology can encompass other embodiments not expressly shown or described herein.

As used herein, the term “and/or” when used in the phrase “A and/or B” means “A, or B, or both A and B.” A similar manner of interpretation applies to the term “and/or” when used in a list of more than two terms. As used herein, the terms “generally” and “approximately” refer to values or characteristics within a range of ±10% from the stated value or characteristic, unless otherwise indicated.