Heat flow in variable polarity plasma arc welds

Abstract

The space shuttle external tank and the space station Freedom are fabricated by the variable polarity plasma arc (VPPA) welding. Heat sink effects (taper) are observed when there are irregularities in the work-piece configuration especially if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, and in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of the previous, present, and consecutive research studies is to investigate the effect of irregularities in the work-piece configuration and fixture differences on the weld bead geometry with the ultimate objective to compensate automatically for the heat sink effects and achieve a perfect weld.