The document summarizes the assembly of modular tooling for the LVSA (Launch Vehicle Stage Adapter). It discusses three phases: generating an assembly plan, subassembling small parts, and assembling the modular tooling on a weld table. The C3 configuration was assembled by installing minis, tombstone stanchions, and flange platforms to create a level surface for the LVSA ring. Shelves were bolted to stanchions to support the ring during welding. Additional modular tooling will be needed at higher levels to complete circumferential welding of the LVSA.

1. Modular Tooling for the LVSA
(Launch Vehicle Stage Adapter)
Miles O’Berry (UAH) and Jacob Anders (Motlow State CC)
Mentor: Justin Littell, EM32
Phase II (Subassembly)
Phase III (Assembly of Modular
Tooling)
Assembly of the C3 configuration (Figure 4) involved
installing (36) minis and (36) tombstone stanchions
through laser tracking. Flange platforms (18) were
installed on top of the minis to create a level datum for
the LVSA segmented ring to sit on. Angle brackets were
bolted to the front face of the tombstone stanchions to
support the shelves (Figure 4).
Acknowledgments
We would like to thank our mentor Justin Littell, for
his guidance and leadership on our summer
internship. We also want to thank: Damon Cleghorn,
Kiersten Dutenhaver, Scot Andrews, Brad Anders,
Mike Ledford, Ronnie Renfroe, Henry Phillips, Tim
Nelson, Mike Terry, Danny Jordan, David Beaty, Ron
Jones, John Comfort, Jon Street, Barry Wilson, David
Arbor, and Logan Thompson for their support over
the summer.
These rings are referred to as
“shelves”. With all the shelves
bolted onto the Robotic Weld Tool
(RWT) table, it will make a
concentric circle for the LVSA to
rest against (Figure 3).
Abstract
Utilization of Self-Reacting Friction Stir Welding
(SR-FSW) requires heavy fixturing in order to
hold parts in place during fit-up, machining, and
welding. Previously, a single “custom” fixture
was designed to weld flight hardware together.
Due to the cost and schedule risk this entailed
development was executed to design an adaptive
tooling concept, i.e. “Modular Tooling”, to allow
the same fixtures to be used for development
and manufacturing of flight hardware for
different stages and projects. In order to
assemble Modular Tooling, various piece parts
must be machined, assembled, and configured for
the hardware.
Objective
Project consisted of three phases
Phase I: Generate Assembly Plan
Phase II: Subassembly of small piece part components
Phase III: Assembly of Modular Tooling on weld table
Shoes are assembled and then
bolted to the wedges. These
“shoes” will be assembled on a
ring and they will be utilized to
push outward on the LVSA panel
sections to make a concentric
cone (Figure 2). Wedges are
utilized for adaptability to the
change in diameter of LVSA.
Phase I (Assembly Plan)
An assembly plan was
prepared to outline every step
necessary to complete
assembly of piece parts and
completed tooling for the
LVSA modular tooling and for
reference on future projects
(Figure 1).
Figure 1: Cover Page
for Assembly Plan
Figure 2: From left to
right piece parts of
shoe, assembled
shoe, and wedge
part.
Figure 3:Assembled
Shelves
Future Work
For completion of
LVSA manufacturing
additional tooling must
be configured. This
requires modular
tooling at elevated
heights for the C1 and
C2 circumferential
weld (Figure 5). With
the C3 configuration
fully assembled, the
tooling itself will weigh
in at approximately
80,000 pounds. The
LVSA, a critical piece
of the SLS will connect
the SLS core stage to
the Interim Cryogenic
Propulsion Stage
(ICPS) while providing
a protective envelope
for the ICPS
propulsion system.
Figure 4
Mini
Tombstone
Stanchions
Flange
Platform
C2
C1
C3
Figure 5: Final Modular
Tooling Configuration
Figure 6: Position of LVSA
on SLS rocket